Mini pocket hole jig system

ABSTRACT

A pocket hole jig system is formed of a plurality of jig segments, wherein each jig segment includes a main body having a drill guide and a lock feature that protrudes outward on a first side of the main body and a recess that protrudes inward on a second side of the main body. The system also includes one or more spacers that have a main body of varying width and a lock feature that protrudes outward on a first side of the main body and a recess that protrudes inward on a second side of the main body. Jig segments and spacers may be connected together by inserting the lock feature of a jig segment or spacer into the recess of an adjacent jig segment or spacer. In one arrangement opposing jig segments and/or spacers lock together with a combination of rotational movement as well as sliding movement.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Utility application Ser. No.16/397,260 which was filed on Apr. 29, 2019, which claims priority toU.S. Provisional Application No. 62/664,335 which was filed on Apr. 30,2018, the entirety of which is incorporated herein fully by reference.

This application also claims priority to U.S. Provisional ApplicationNo. 62/785,967 which was filed Dec. 28, 2018, the entirety of which isalso incorporated herein fully by reference.

FIELD OF THE DISCLOSURE

This disclosure relates generally to woodworking tools. Morespecifically and without limitation, this disclosure relates to aportable pocket hole jig system that provides a plurality of improvedfunctions as well as ease of use.

BACKGROUND OF THE DISCLOSURE

Pocket hole jigs are old and well known in the art. A pocket hole jig isconfigured to hold a stepped drill bit at an angle so as to facilitatedrilling into a workpiece at an angle. A screw is then inserted into thestepped pocket hole which joins two workpieces together thereby forminga pocket hole joint which is known for being easy to assemble and alignas well as having excellent strength while also allowing for hiding ofthe screws used to form the joint. An example of a pocket hole jigsystem is owned by Applicant and assigned U.S. Pat. No. 7,798,750 andU.S. patent application Ser. No. 11/894,253 entitled Drill Guide WithRemovable Clamp Retainer which was filed on Aug. 20, 2007 and issued onSep. 21, 2010, which is fully incorporated by reference herein, alongwith all related applications and patents. Another example of a pockethole jig system is owned by Applicant and assigned U.S. Pat. No.8,231,313 and U.S. patent application Ser. No. 11/947,722 entitledAdjustable Holding System which was filed on Nov. 29, 2007 and issued onJul. 31, 2012, which is fully incorporated by reference herein, alongwith all related applications and patents.

While pocket hole jigs and the resulting pocket hole joinery theyproduce are a great improvement over prior forms of joinery, such asdowel joinery, dovetail joinery and the like, existing pocket hole jigssuffer from many disadvantages. Namely, setting up existing pocket holejig systems is complex and not intuitive. This complexity requires manyusers to review the set-up instructions before use and even when doingso users are often confused and unsure of themselves. In addition, whenpocket hole jig systems are set up, it is difficult for a user to knowif the jig and drill bit are properly configured for their intended use.This often requires the user to do a test run before use to ensure thatthe jig and drill bit are properly set up for the workpieces they areusing. This takes an unnecessary amount of time and unnecessarilyconsumes material and screws. In addition, due to the complexity andnot-intuitive nature of the set-up process, pocket hole jigs are oftenset up for non-optimal performance. When this occurs, the resultingpocket hole joinery is not as strong as it could otherwise be and/or thewrong screws are used.

As such, for all these reasons existing pocket hole jig systems are toodifficult to set-up, they are too time consuming to set up and they aretoo easy to improperly set-up.

Therefore, for all the reasons stated above, and the reasons statedbelow, there is a need in the art for a mini pocket hole jig system thatimproves upon the state of the art.

Another object of the disclosure is to provide a mini pocket hole jigsystem that provides improved functionality over prior art systems.

Yet another object of the disclosure is to provide a mini pocket holejig system that provides improved features over prior art systems.

Another object of the disclosure is to provide a mini pocket hole jigsystem that is relatively inexpensive.

Yet another object of the disclosure is to provide a mini pocket holejig system that is easy to use.

Another object of the disclosure is to provide a mini pocket hole jigsystem that is intuitive to use.

Yet another object of the disclosure is to provide a mini pocket holejig system that is strong and robust.

Another object of the disclosure is to provide a mini pocket hole jigsystem that can be used in many applications.

Yet another object of the disclosure is to provide a mini pocket holejig system that is practically impossible to improperly set-up.

Another object of the disclosure is to provide a mini pocket hole jigsystem that provides unique functionality.

Yet another object of the disclosure is to provide a mini pocket holejig system that is fast to use and fast to set-up.

Another object of the disclosure is to provide a mini pocket hole jigsystem that is safe to use.

Yet another object of the disclosure is to provide a mini pocket holejig system that saves time.

Another object of the disclosure is to provide a mini pocket hole jigsystem that has a compact size.

Yet another object of the disclosure is to provide a mini pocket holejig system that is adjustable, in depth as well as width.

Another object of the disclosure is to provide a mini pocket hole jigsystem that has a long useful life.

Yet another object of the disclosure is to provide a mini pocket holejig system that can be used on outside edges on workpieces as well asinside corners.

Another object of the disclosure is to provide a mini pocket hole jigsystem that is high quality.

Yet another object of the disclosure is to provide a mini pocket holejig system that improves efficiencies.

Another object of the disclosure is to provide a mini pocket hole jigsystem that is fun to use.

Yet another object of the disclosure is to provide a mini pocket holejig system that improves the quality of the products made using thedevice.

Another object of the disclosure is to provide a mini pocket hole jigsystem that eliminates the need to review the set-up instructions toproperly set up the system.

Yet another object of the disclosure is to provide a mini pocket holejig system that provides a visual feedback that the system is properlyset-up.

These and other objects, features, or advantages of the disclosure willbecome apparent from the specification, figures and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top rear perspective view of a first embodiment of a minipocket hole jig system, the view showing a pair of jig segments having atail section connected to the forward end of the jig segments, the viewshowing the two jig segments extending in parallel spaced relation toone another and connected by a spacer positioned between the jigsegments, the view showing the tail sections having a sliding stopfeature positioned within the tail sections that slides in a slot in thesides of the tail section, the view showing openings in the tail sectionthat show indicia that indicate the workpiece thickness when the stopfeature is visible through the opening, the view showing a lock featureextending outward from the left side of the left-positioned jig segment,the view showing protrusions or stop features the extend outward fromthe side of the jig segment on each of the front and rear sides of thelock feature;

FIG. 2 is a bottom front perspective view of the mini pocket hole jigsystem shown in FIG. 1, the view showing a flat bottom planar surfacethat extends across the aligned jig segments as well as themiddle-positioned spacer, the view showing the flat bottom planarsurface having a layer of grippy material with a high coefficient offriction, the view showing bore formed by the drill guide extendingthrough the bottom surface of the jig segments at an angle, the viewshowing the stop feature positioned within the hollow interior of thetail section;

FIG. 3 is a top rear perspective view of a single jig segment and tailsection of the mini pocket hole jig system shown in FIG. 1, the viewshowing a jig segment with a tail section connected to the forward endof the jig segment;

FIG. 4 is a top rear perspective view of a single jig segment and tailsection of the mini pocket hole jig system shown in FIG. 1, the viewshowing a jig segment and a tail section exploded from one another, theview showing the rearward end of the tail section aligned to slide downover the connector at the forward end of the jig segment therebyconnecting the tail section to the jig segment;

FIG. 5 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-4, the view showing two jig segments having main bodieswith tail sections attached and an exploded spacer, the view showing onejig segment and spacer upright and the other jig segment and spacerupside down, the view showing a planar bottom surface to the jig segmentand spacer that includes a layer of grippy material, the view showingthe upper surface of the jig segment having a large-pattern honeycombstructure for support and rigidity as well as material and weightsavings, the view showing the tail section being hollow with stopfeature positioned therein and visible through openings at variousworkpiece thicknesses, the view showing the upper spacer and main bodyhaving a protrusion extending outward from the side of the jig segmentin front of the lock feature and another protrusion extending outwardfrom the side of the jig segment rearward of the lock feature, the viewshowing the lower spacer and jig segment have a pair of laterallyextending bars with a space between positioned in front of a receiver inthe side of the jig segment and another pair of laterally extending barswith a space between positioned rearward of the receiver in the side ofthe jig segment wherein the space between the bars that serve to receivethe protrusions when the lock feature of one jig segment or spacer isreceived within the receiver of another jig segment or spacer;

FIG. 6 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-4, and FIG. 5, the view showing two jig segments withtail sections attached and an exploded spacer, the view showing one jigsegment and spacer upright and the other jig segment and spacer upsidedown, the view showing the bottom surface of the spacer and jig segmenthaving strips of grippy material thereon;

FIG. 7 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-5, and FIG. 5, and FIG. 6, the view showing two jigsegments with tail sections attached and an exploded spacer, the viewshowing one jig segment and spacer upright and the other jig segment andspacer upside down;

FIG. 8 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-5, and FIG. 5, and FIG. 6, and FIG. 7, the view showingtwo jig segments with tail sections attached and an exploded spacer, theview showing one jig segment and spacer upright and the other jigsegment and spacer upside down;

FIG. 9 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-5, and FIG. 5, and FIG. 6, and FIG. 7 and FIG. 8, theview showing two jig segments with tail sections attached and anexploded spacer, the view showing one jig segment and spacer upright andthe other jig segment and spacer upside down;

FIG. 10 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-5, and FIG. 5, and FIG. 6, and FIG. 7 and FIG. 8, andFIG. 9, the view showing two jig segments with tail sections attachedand an exploded spacer, the view showing one jig segment and spacerupright and the other jig segment and spacer upside down, the viewshowing the upper surface of the spacer and jig segment having asmall-pattern honeycomb structure for support and rigidity as well asmaterial and weight savings;

FIG. 11 is a perspective view of artistic renderings of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIGS. 1-5, and FIG. 5, and FIG. 6, and FIG. 7 and FIG. 8, andFIG. 9, and FIG. 10, the view showing two jig segments with tailsections attached, the view showing one jig segment upright and theother jig segment upside down, the view showing a protrusion connectedto the upper edge of the jig segment forward of the lock feature and aprotrusion connected to the lower edge of the jig segment rearward ofthe lock feature, the view showing a similarly aligned recess connectedto the upper surface forward of a receiver on the opposite side of thejig segment and a recess connected to the lower edge of the jig segmentrearward of the receiver, wherein the recesses are configured to receivethe protrusions in locking fashion when the lock feature of one jigsegment or spacer is positioned within the receiver of another jigsegment or spacer;

FIG. 12 is a perspective view of another embodiment of a mini pockethole jig system that is similar to that shown in FIG. 11 the viewshowing a single recess in the side of the jig segment rearward of thereceiver;

FIG. 13 is a perspective view of another embodiment of a mini pockethole jig system that is similar to that shown in FIG. 11, the viewshowing two jig segments and two spacers upside down, the view showing aprotrusion connected to the upper edge of the jig segment or spacerforward of the lock feature and a protrusion connected to the lower edgeof the jig segment or spacer rearward of the lock feature, the viewshowing a similarly aligned recess connected to the upper surfaceforward of a receiver on the opposite side of the jig segment or spacerand a recess connected to the lower edge of the jig segment or spacerrearward of the receiver, wherein the recesses are configured to receivethe protrusions in locking fashion when the lock feature of one jigsegment or spacer is positioned within the receiver of another jigsegment or spacer and they are twisted together;

FIG. 14 is a perspective view of an artistic rendering of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIG. 13, the view showing two jig segments and a spacer inexploded fashion, the view showing a protrusion connected to the upperedge of the jig segment and spacer forward of the lock feature and ahidden protrusion connected to the lower edge of the jig segment andspacer rearward of the lock feature, the view showing a similarlyaligned recess connected to the upper surface forward of a receiver onthe opposite side of the jig segment and spacer and a recess connectedto the lower edge of the jig segment and spacer rearward of thereceiver, wherein the recesses are configured to receive the protrusionsin locking fashion when the lock feature of one jig segment or spacer ispositioned within the receiver of another jig segment or spacer and theyare twisted together;

FIG. 15 is a perspective view of an artistic rendering of anotherembodiment of a mini pocket hole jig system, the view showing two jigsegments that include a pair of receivers in the side of the jig segmentthat include a key hole shaped member that forms receiver one toward theforward end of the main body and one toward the rearward end of the mainbody, these receivers receive lock features therein that facilitateconnection by laterally sliding the two jig segments relative to oneanother in accordance with the arrows shown on the drawing;

FIG. 16 is a perspective view of an artistic rendering of anotherembodiment of a mini pocket hole jig system that is similar to thatshown in FIG. 14, the view showing two jig segments connected at theirmiddle and rotated with respect to one another, the view showing arecess connected to the upper surface forward of a receiver on theopposite side of the jig segment from a protrusion and a recessconnected to the lower edge of the jig segment rearward of the receiver,wherein the recesses are configured to receive the protrusions inlocking fashion when the lock feature of one jig segment is rotated intothe receiver of another jig segment and they are twisted togetherrelative to one another in accordance with the arrows shown on thedrawing;

FIG. 17 is a perspective view of an artistic rendering of anotherembodiment of a mini pocket hole jig system, the view showing two jigsegments having lock feature and receiver take the form of a dove-tailarrangement or locking rail and groove arrangement wherein the grooveand rail extend a majority of the portion of the length of the jigsegments wherein the two jig segments are connected to one another bysliding the lock feature of one jig segment into the groove of the otherjig segment and sliding them until they are in a parallel aligned state;

FIG. 18 is a perspective view of stepped drill bit having a plurality ofrings around the shaft of the drill bit, wherein each indicia alsoincludes a numerical value for the workpiece thickness, the view alsoshowing a stop collar with an alignment feature that is formed of a holein the stop collar that is configured to be aligned with the alignmentfeature;

FIG. 19 is a perspective view of stepped drill bit similar to that shownin FIG. 18, the view showing the stepped drill bit having a plurality ofmeasurement indicia laser etched into the shaft of the drill bit, eachmeasurement indicia having a numerical value that is held within acircle that corresponds in size and shape to an alignment feature in astop collar positioned around the shaft of the stepped drill bit, theview showing the alignment feature being a circular opening in the stopcollar;

FIG. 20 is a perspective view of stepped drill bit similar to that shownin FIG. 18 and FIG. 19, the view showing the stepped drill bit having aplurality of measurement indicia laser etched into the shaft of thedrill bit, each measurement indicia having a numerical value that isheld within a circle that corresponds in size and shape to an alignmentfeature in a stop collar positioned around the shaft of the steppeddrill bit, the view showing the alignment feature being a half-circularopening in the stop collar;

FIG. 21 is a perspective view of workpiece thickness gauge having anAllen wrench extending through the workpiece thickness gauge, the viewshowing the workpiece thickness gauge having a plurality of steps withindicia that correspond to various workpiece thicknesses;

FIG. 22 is a perspective view of a workpiece thickness gauge similar tothat showing in FIG. 20 the view showing a key chain ring attached tothe workpiece thickness gauge instead of an Allen wrench, the viewshowing the workpiece thickness gauge having a plurality of steps withindicia that correspond to various workpiece thicknesses;

FIG. 23 is a perspective view of stepped drill bit similar to that shownin FIG. 18 and FIG. 19, the view showing the stepped drill bit having aplurality of measurement indicia laser etched into the shaft of thedrill bit, each measurement indicia having a numerical value that isheld within a circle that corresponds in size and shape to an alignmentfeature in a stop collar positioned around the shaft of the steppeddrill bit, the view showing the alignment feature being a circularopening in the stop collar;

FIG. 24 is a perspective view of a mini pocket hole jig system similarto that shown in FIGS. 1-17 clamped to workpiece with a clamp;

FIG. 25 is a perspective view of another embodiment of a workpiecethickness gauge having a an embedded Allen wrench and a plurality ofindicia that correspond to various workpiece thicknesses;

FIG. 26 is another perspective view of the workpiece thickness gaugeshown in FIG. 25;

FIG. 27 is another perspective view of the workpiece thickness gaugeshown in FIG. 25;

FIG. 28 is a perspective view of another embodiment of a mini pockethole jig system, the view showing two jig segments joined together attheir forward end by the connection of a lock feature of one jig segmentinto the receiver of the other jig segment; the view showing a receiverin the forward end of one of the jig segments, the view showing a groovein the sidewall of the jig segment rearward of the receiver with a pairof bars extending across the groove that form a recess between the barsthat are configured to receive a protrusion therein when two jigsegments are connected together and rotated in parallel alignment;

FIG. 29 is another perspective view of the embodiment of a mini pockethole jig system shown in FIG. 28, the view showing two jig segmentsjoined together at their forward end by the connection of a lock featureof one jig segment into the receiver of the other jig segment; the viewshowing a lock feature in the forward end of one of the jig segments,the view showing a protrusion in the sidewall of the gig segmentrearward of the lock feature that is configured to be received withinthe groove and between the bars of an adjacent jig segment when two jigsegments are connected together and fully rotated in parallel alignment;

FIG. 30 is bottom perspective view of the embodiment of a mini pockethole jig system shown in FIG. 28, the view showing two jig segmentsjoined together at their forward end by the connection of a lock featureof one jig segment into the receiver of the other jig segment; the viewshowing a receiver in the forward end of one of the jig segments, theview showing a groove in the sidewall of the jig segment rearward of thereceiver with a pair of bars extending across the groove that form arecess between the bars that are configured to receive a protrusiontherein when two jig segments are connected together and rotated inparallel alignment;

FIG. 31 is a close-up side elevation view of the forward end of theembodiment of a mini pocket hole jig system shown in FIG. 28, the viewshowing the receiver in the sidewall adjacent the forward end of the jigsegment, the view showing the connector in the forward end of the jigsegment that is used to connect a tail section;

FIG. 32 is a close-up perspective view of the forward end of theembodiment of a mini pocket hole jig system shown in FIG. 28, the viewshowing the lock feature extending outward from the sidewall adjacentthe forward end of one jig segment about to be inserted into thereceiver in the sidewall adjacent the forward end of the other jigsegment, the view showing the two jig segments rotated at about aperpendicular manner to one another to facilitate insertion of the lockfeature of one jig segment into the receiver of the other jig segment;

FIG. 33 is a close-up perspective view of the forward end of theembodiment of a mini pocket hole jig system shown in FIG. 28, the viewshowing the lock feature extending outward from the sidewall adjacentthe forward end of one jig segment that has been inserted into thereceiver in the sidewall adjacent the forward end of the other jigsegment, the view showing the two jig segments rotated at about aperpendicular manner to one another to facilitate insertion of the lockfeature of one jig segment into the receiver of the other jig segment;

FIG. 34 is a close-up perspective section view of the forward end of theembodiment of a mini pocket hole jig system shown in FIG. 28, the viewshowing the lock feature extending outward from the sidewall adjacentthe forward end of one jig segment inserted into the receiver in thesidewall adjacent the forward end of the other jig segment, the viewshowing the two jig segments rotated to a parallel alignment with oneanother to facilitate locking of the lock feature of one jig segmentinto the receiver of the other jig segment, the section view cuttingthrough the approximate center of the lock feature and receiver of thejig segments from top to bottom;

FIG. 35 is a perspective section view of the embodiment of a mini pockethole jig system shown in FIG. 28, the view showing the lock featureextending outward from the sidewall adjacent the forward end of one jigsegment inserted into the receiver in the sidewall adjacent the forwardend of the other jig segment, the view showing the two jig segmentsrotated to a parallel alignment with one another to facilitate lockingof the lock feature of one jig segment into the receiver of the otherjig segment, the section view cutting through the approximate center ofthe lock feature and receiver of the jig segments from the forward endto the rearward end of the jig segments;

FIG. 36 is a perspective exploded view of the embodiment of a minipocket hole jig system shown in FIG. 28, the view showing the tailsection exploded from the forward end of the jig segment, the viewshowing the stop feature exploded from the tail section, the viewshowing the tail section having a hollow interior that receives the stopfeature therein, the view showing a pair of opposed grooves with stopstherein that are aligned to fit various workpiece thicknesses;

FIG. 37 is another perspective exploded view of the embodiment of a minipocket hole jig system shown in FIG. 28, the view showing the tailsection exploded from the forward end of the jig segment;

FIG. 38 is another perspective view of the embodiment of a mini pockethole jig system shown in FIG. 28, the view showing the tail sectionattached to the forward end of the jig segment;

FIG. 39 is a perspective view of another embodiment of a mini pockethole jig system, the view showing another embodiment of a tail sectionthat does not have the hollow interior and slot as is presented in FIGS.36-38, the view showing the stop feature fitting around the lower end ofthe tail section and having a pair of flanges with guides that fitwithin a groove that extends along the lower sides of the tail section;

FIG. 40 is a perspective exploded view of the mini pocket hole jigsystem shown in FIG. 39, the view showing the tail section exploded fromthe jig segment, the view showing the stop feature exploded from thetail section;

FIG. 41 is a perspective view of the tail section of a mini pocket holejig system shown in FIG. 39, the view showing the stop feature attachedto the bottom side of the tail section and engaged within the groove ofthe tail section;

FIG. 42 is a bottom perspective view of the tail section of a minipocket hole jig system shown in FIG. 39, the view showing the stopfeature attached to the bottom side of the tail section and engagedwithin the groove of the tail section, the view showing the tail sectionconnected to the forward end of the jig segment;

FIG. 43 is a perspective view of another embodiment of a mini pockethole jig system, the view showing adjacent jig segments that connect toone another with a combination of rotational movement as well as slidingmovement, the view showing the jig segments having a lock featureextending outward from the forward end of the jig segment as well as alock feature extending outward from the rearward end of the jig segmenton one side of the jig segment, the view showing a receiver positionedin the forward end of the jig segment as well as a receiver positionedin the rearward end of the jig segment on an opposite side of the jigsegment as the lock features, the view showing the adjacent jig segmentsconnected at their forward ends by the insertion of a forward lockfeature of one jig segment in the forward receiver of the other jigsegment, the view showing the adjacent jig segments rotated at an angleto one another, the view showing semi-circular screw receiverspositioned in the side walls of the jig segments at about their middle,the view showing a plurality of vertically extending ramps positioned inthe sidewalls that protrude outward slightly from the sidewalls thathelp to push the adjacent jig segments away from one another when theyare slid into a fully locked position, the view showing the forwardpositioned receiver as a hole in the forward end of the sidewall of thejig segment, the view showing the rearward positioned receiver openingto a slot in the lower surface of the sidewall so as to facilitateinsertion of the lock feature when the two jig segments are rotatedtogether;

FIG. 44 is another perspective view of the mini pocket hole jig systemshown in FIG. 43 the view showing another angle of the mini pocket holejig system;

FIG. 45 is a side elevation view of the mini pocket hole jig systemshown in FIG. 43;

FIG. 46 is another side elevation view of the mini pocket hole jigsystem shown in FIG. 43;

FIG. 47 is a rear elevation view of the mini pocket hole jig systemshown in FIG. 43;

FIG. 48 is a top elevation view of the mini pocket hole jig system shownin FIG. 43

FIG. 49 is a bottom elevation view of the mini pocket hole jig systemshown in FIG. 43;

FIG. 50 is a bottom perspective view of the mini pocket hole jig systemshown in FIG. 43, the view showing the two jig segments rotated into aparallel alignment with one another, the view showing the rearward lockfeature of one of the jig segments positioned within the rearwardreceiver of the other jig segment, the view showing the two jig segmentsstaggered with respect to one another, or said another way, the viewshowing the two jig segments laterally offset from one another;

FIG. 51 is a top perspective view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned arrangement but laterallyoffset alignment shown in FIG. 50;

FIG. 52 is a top elevation view of the mini pocket hole jig system shownin FIG. 43 in the parallel aligned arrangement but laterally offsetalignment shown in FIG. 50;

FIG. 53 is a side elevation view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned arrangement but laterallyoffset alignment shown in FIG. 50;

FIG. 54 is another side elevation view of the mini pocket hole jigsystem shown in FIG. 43 in the parallel aligned arrangement butlaterally offset alignment shown in FIG. 50;

FIG. 55 is a bottom elevation view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned arrangement but laterallyoffset alignment shown in FIG. 50

FIG. 56 is a top elevation view of the mini pocket hole jig system shownin FIG. 43 in the parallel aligned and laterally aligned arrangementafter the two jig segments have rotated with respect to one another aswell as after the two jig segments have been laterally slid with respectto one another into a fully locked position;

FIG. 57 is a bottom elevation view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned and laterally alignedarrangement shown in FIG. 56;

FIG. 58 is a side elevation view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned and laterally alignedarrangement shown in FIG. 56;

FIG. 59 is another side elevation view of the mini pocket hole jigsystem shown in FIG. 43 in the parallel aligned and laterally alignedarrangement shown in FIG. 56;

FIG. 60 is a rear elevation view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned and laterally alignedarrangement shown in FIG. 56;

FIG. 61 is a front elevation view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned and laterally alignedarrangement shown in FIG. 56;

FIG. 62 is a perspective view of the mini pocket hole jig system shownin FIG. 43 in the parallel aligned and laterally aligned arrangementshown in FIG. 56;

FIG. 63 is a bottom perspective view of the mini pocket hole jig systemshown in FIG. 43 in the parallel aligned and laterally alignedarrangement shown in FIG. 56;

FIG. 64 is a perspective exploded view of a clamp pad attachmentmechanism for use with the mini pocket hole jig system presented herein,the view showing the base exploded from adjustment member, the viewshowing the connector exploded from the base;

FIG. 65 is a top elevation view of the clamp pad attachment mechanismshown in FIG. 64, the view showing the connector connected to the base,the view showing the adjustment member connected to the base;

FIG. 66 is a side elevation view of the clamp pad attachment mechanismshown in FIG. 64;

FIG. 67 is another side elevation view of the clamp pad attachmentmechanism shown in FIG. 64;

FIG. 68 is a bottom elevation view of the clamp pad attachment mechanismshown in FIG. 64;

FIG. 69 is a front elevation view of the clamp pad attachment mechanismshown in FIG. 64;

FIG. 70 is a rear elevation view of the clamp pad attachment mechanismshown in FIG. 64;

FIG. 71 is a top perspective view of the clamp pad attachment mechanismshown in FIG. 64;

FIG. 72 is a top elevation view of the adjustment member of the clamppad attachment mechanism shown in FIG. 64;

FIG. 73 is a bottom elevation view of the adjustment member of the clamppad attachment mechanism shown in FIG. 64;

FIG. 74 is a side elevation view of the adjustment member of the clamppad attachment mechanism shown in FIG. 64;

FIG. 75 is another side elevation view of the adjustment member of theclamp pad attachment mechanism shown in FIG. 64;

FIG. 76 is a front elevation view of the adjustment member of the clamppad attachment mechanism shown in FIG. 64;

FIG. 77 is a rear elevation view of the adjustment member of the clamppad attachment mechanism shown in FIG. 64;

FIG. 78 is a perspective view of the adjustment member of the clamp padattachment mechanism shown in FIG. 64;

FIG. 79 is a top elevation view of the base of the clamp pad attachmentmechanism shown in FIG. 64;

FIG. 80 is a bottom elevation view of the base of the clamp padattachment mechanism shown in FIG. 64;

FIG. 81 is a side elevation view of the base of the clamp pad attachmentmechanism shown in FIG. 64;

FIG. 82 is another side elevation view of the base of the clamp padattachment mechanism shown in FIG. 64;

FIG. 83 is front elevation view of the base of the clamp pad attachmentmechanism shown in FIG. 64;

FIG. 84 is another side elevation view of the base of the clamp padattachment mechanism shown in FIG. 64;

FIG. 85 is a perspective view of the base of the clamp pad attachmentmechanism shown in FIG. 64;

FIG. 86 is a top elevation view of a connector of the clamp padattachment mechanism shown in FIG. 64;

FIG. 87 is a bottom elevation view of a connector of the clamp padattachment mechanism shown in FIG. 64;

FIG. 88 is a side elevation view of a connector of the clamp padattachment mechanism shown in FIG. 64;

FIG. 89 is another side elevation view of a connector of the clamp padattachment mechanism shown in FIG. 64;

FIG. 90 is a perspective view of a connector of the clamp pad attachmentmechanism shown in FIG. 64;

FIG. 91 is a perspective view of the mini pocket hole jig system shownin FIGS. 43-90 attached to the end of a workpiece by a clamp, the viewshowing the clamp pad attachment mechanism attached to the jig segment,the view showing the tail section attached to the jig segment; the viewshowing the clamp pad held within the clamp pad attachment mechanism,the view showing the clamp clamping the mini pocket hole jig system tothe workpiece;

FIG. 92 is another perspective view of the mini pocket hole jig systemshown in FIG. 91 attached to the end of a workpiece by a clamp;

FIG. 93 is a perspective view of the mini pocket hole jig system shownin FIG. 91 and FIG. 92 attached to the end of a workpiece by a clamp,the view showing a different type of clamp as used in FIG. 91 and FIG.92;

FIG. 94 is another perspective view of the mini pocket hole jig systemshown in FIG. 93 attached to the end of a workpiece by a clamp;

FIG. 95 is a perspective exploded view of the mini pocket hole jigsystem shown in FIGS. 43-90, the view showing two jig segments connectedtogether in side-to-side locked alignment, the view showing an explodedclam pad attachment mechanism positioned above the jig segments, theview showing the connector aligned to be inserted within an opening inthe top surface of one of the jig segments so as to facilitateconnection of the clamp pad attachment mechanism to a jig segment;

FIG. 96 is a close up top elevation view of a portion the mini pockethole jig system shown in FIGS. 43-90, the view showing two jig segmentsconnected together in side-to-side but offset alignment, the viewshowing ramps of the adjacent jig segments offset from one another priorto the two jig segments being slid laterally with respect to one anotherinto a fully locked arrangement;

FIG. 97 is a close up top elevation view of a portion the mini pockethole jig similar to that shown in FIG. 96, the view showing two jigsegments connected together in side-to-side and laterally alignedalignment, the view showing ramps of the adjacent jig segments inalignment with one another thereby forcing the two jig segments awayfrom one another so as to facilitate locking engagement and a tight fitbetween adjacent jig segments and/or spacers;

FIG. 98 is a side elevation view of another embodiment of a workpiecethickness gauge having a main body with an Allen wrench extendingthrough the main body, the view showing the main body having a pluralityof indicia that correlate to workpiece thickness;

FIG. 99 is an end elevation view of the workpiece thickness gauge shownin FIG. 98;

FIG. 100 is a top elevation view of the workpiece thickness gauge shownin FIG. 98;

FIG. 101 is another end elevation view of the workpiece thickness gaugeshown in FIG. 98;

FIG. 102 is another side elevation view of the workpiece thickness gaugeshown in FIG. 98;

FIG. 103 is a perspective view of the workpiece thickness gauge shown inFIG. 98;

FIG. 104 is another perspective view of the workpiece thickness gaugeshown in FIG. 98;

FIG. 105 is a perspective view of the workpiece thickness gauge shown inFIG. 98, the view showing the workpiece thickness gauge tightening thelock screw of a stop collar positioned around the shaft of a steppeddrill bit;

FIG. 106 is another perspective view of the workpiece thickness gaugeshown in FIG. 98, the view showing the workpiece thickness gaugetightening the lock screw of a stop collar positioned around the shaftof a stepped drill bit;

FIG. 107 is an elevation view of the workpiece thickness gauge shown inFIG. 98, the view showing the workpiece thickness gauge measuring thethickness of a workpiece;

FIG. 108 is a close up elevation view of the workpiece thickness gaugeshown in FIG. 107, the view showing the workpiece thickness gaugemeasuring the thickness of a workpiece;

FIG. 109 is a perspective exploded view of the mini pocket hole jigsystem shown in FIGS. 43-97, the view showing the tail section explodedfrom the end of the jig segment;

FIG. 110 is another perspective exploded view of the mini pocket holejig system shown in FIG. 109, the view showing the tail section explodedfrom the end of the jig segment;

FIG. 111 is a bottom perspective exploded view of the mini pocket holejig system shown in FIG. 109, the view showing the tail section explodedfrom the end of the jig segment;

FIG. 112 is another perspective view of the mini pocket hole jig systemshown in FIG. 109, the view showing the tail section partially slid overthe connector at the end of the jig segment;

FIG. 113 is a top elevation view of the mini pocket hole jig systemshown in FIGS. 43-97 and FIGS. 109-112, the view showing two jigsegments with tail sections connected to the ends of the jig segments,the view showing the two jig segments connected in parallel spacedrelation to one another with a spacer positioned between the two jigsegments;

FIG. 114 is a bottom elevation view of the mini pocket hole jig systemshown in FIG. 113;

FIG. 115 is a side elevation view of the mini pocket hole jig systemshown in FIG. 113;

FIG. 116 is another side elevation view of the mini pocket hole jigsystem shown in FIG. 113;

FIG. 117 is an elevation view of the rear side of the mini pocket holejig system shown in FIG. 113;

FIG. 118 is an elevation view of the front side of the mini pocket holejig system shown in FIG. 113;

FIG. 119 is a perspective view of the mini pocket hole jig system shownin FIG. 113;

FIG. 120 is another perspective view of the mini pocket hole jig systemshown in FIG. 113;

FIG. 121 is a bottom perspective view of the mini pocket hole jig systemshown in FIG. 113;

FIG. 122 is a perspective view of the mini pocket hole jig system shownin FIG. 113, the view showing the forward end of the mini pocket holejig system;

FIG. 123 is another perspective view of the mini pocket hole jig systemshown in FIG. 113, the view showing the forward end of the mini pockethole jig system;

FIG. 124 is a bottom perspective view of the mini pocket hole jig systemshown in FIG. 113, the view showing the forward end of the mini pockethole jig system;

FIG. 125 is another bottom perspective view of the mini pocket hole jigsystem shown in FIG. 113, the view showing the forward end of the minipocket hole jig system

FIG. 126 is an exploded perspective view of the mini pocket hole jigsystem shown in FIG. 113, the view showing the spacer exploded from thejig segments, the view showing the tail sections attached to the jigsegments;

FIG. 127 is another exploded perspective view of the mini pocket holejig system shown in FIG. 113, the view showing the spacer exploded fromthe jig segments, the view showing the tail sections attached to the jigsegments;

FIG. 128 is another exploded perspective view of the mini pocket holejig system shown in FIG. 113, the view showing the bottom of the minipocket hole jig system, the view showing the spacer exploded from thejig segments, the view showing the tail sections attached to the jigsegments.

SUMMARY OF THE DISCLOSURE

The figures show one or more embodiments of a mini pocket hole jigsystem. The pocket hole jig system is formed of a plurality of jigsegments, wherein each jig segment includes a main body having a drillguide and at least one lock feature that protrudes outward on a firstside of the main body and at least one recess that protrudes inward on asecond side of the main body, wherein the lock feature(s) are oppositethe recess(es). The system also includes one or more spacers that have amain body of varying widths and at least one lock feature that protrudesoutward on a first side of the main body and at least one recess thatprotrudes inward on a second side of the main body, wherein the lockfeature(s) are opposite the recess(es). Jig segments and spacers may beconnected together by inserting the lock feature(s) of a jig segment orspacer into the recess(es) of an adjacent jig segment or spacer. In thisway, a mini pocket hole jig may be formed of any number of jig segmentsspaced apart from one another at practically any spacing to form groupsof pocket holes at various spacing. A tail section is connected in aremovable manner to the forward end of the jig segments and/or spacersand include a stop feature that is positioned on and/or within the tailsection and is spring biased and rides in slot that includes a pluralityof stops that correspond to common workpiece thicknesses. The tailsection includes a plurality of indicia formed of an opening in the tailsection, such that when the stop feature is visible through an opening,this indicates the corresponding workpiece thickness. The clampingsurface of the jig segments and spacers includes a layer of materialthat has a high coefficient of friction so as to help hold the jig on aworkpiece with less clamping force.

DETAILED DESCRIPTION OF THE DISCLOSURE

In the following detailed description, reference is made to theaccompanying drawings which form a part hereof, and in which is shown byway of illustration specific embodiments in which the disclosure may bepracticed. These embodiments are described in sufficient detail toenable those skilled in the art to practice the disclosure, and it is tobe understood that other embodiments may be utilized and thatmechanical, procedural, and other changes may be made without departingfrom the spirit and scope of the disclosure(s). The following detaileddescription is, therefore, not to be taken in a limiting sense, and thescope of the disclosure(s) is defined only by the appended claims, alongwith the full scope of equivalents to which such claims are entitled.

As used herein, the terminology such as vertical, horizontal, top,bottom, front, back, end, sides, left, right, and the like arereferenced according to the views, pieces, parts, components and figurespresented. It should be understood, however, that the terms are usedonly for purposes of description, and are not intended to be used aslimitations. Accordingly, orientation of an object or a combination ofobjects may change without departing from the scope of the disclosure.

While a number of embodiments are presented herein, unless statedotherwise, it is to be understood that the teaching of one embodimentapplies to all other embodiments.

System: With reference to the figures, a mini pocket hole jig system 10(or pocket hole jig system 10 or simply system 10) is presented. Thepocket hole jig system 10 is formed of any suitable size, shape anddesign and is configured to facilitate drilling pocket holes in variousworkpieces in various configurations. In the arrangement shown, as oneexample, the pocket hole jig system 10 has a top side 12, a bottom side14, a forward side 16, a rearward side 18, a left side 20, and a rightside 22. The system 10 includes a plurality of jig segments 24 having amain body 26 having a left side 28, a right side 30, a forward end 32, arearward end 34, a top side 36, a clamping surface 38, or bottom side, adrill guide 40, an opening 42, a lock feature 44, and a receiver 46among other components and features. The system 10 includes a pluralityof spacers 48 having a main body 50 having a left side 52, a right side54, a forward end 56, a rearward end 58, a top side 60, a clampingsurface 62, or bottom side, a lock feature 64, and a receiver 66, amongother components and features. The system 10 includes a plurality oftail sections 68 having a main body 70 having a left side 72, a rightside 74, a forward end 76, a rearward end 78, a top side 80, a clampingsurface 82, or bottom side, a hollow interior 84, a slot 86 having aplurality of stops 88, a stop feature 90, and an indicator 92 having aplurality of openings 94, among other components and features. Thesystem 10 includes a workpiece thickness gauge 94 having a main body 96,indicia 98 and a plurality of steps 156 that is in some examplesconnected to an Allen wrench 100, among other components and features.The system 10 includes a stepped drill bit 102 having a connection end104 and a drilling end 106 and indicia 108, among other components andfeatures. The system 10 includes a stop collar 110 having an alignmentfeature 112, and a fastener 114, among other components and features.

Interchangeability of Jig Segments and Spacers: It is important to notethat in the arrangement shown herein both the main body 26 of jigsegments 24 as well as spacers 48 include similar if not identical lockfeatures 44 and/or receivers 46 as well as other matching features. Assuch, jig segments 24 and spacers 48 may be connected to one anotherand/or each other in an interchangeable and identical side-by-sidemanner. As such, reference to how two jig segments 24 connect to oneanother shall apply equally to how two spacers 48 connect together aswell as how a jig segment 24 and spacer 48 connect together. As such, toavoid redundancy, reference to how two jig segments 24 connect to oneanother shall imply a connection to a spacer 48 as well, unless statedotherwise.

Jig Segments: Jig segments 24 are formed of any suitable size, shape anddesign and are configured to be used individually to form pocket holesas well as to be joined with other jig segments 24, tail sections 68and/or spacers 48 to form a pocket hole jig comprised of multiple jigsegments 24, tail sections 68 and/or spacers 48. In the arrangementshown, as one example, jig segments 24 include a main body 26. Main body26 is formed of any suitable size, shape and design and is configured tobe the main structural member of jig segment 24. Main body 26 may beformed of a single monolithic and unitary piece that is formed bymolding, machining, 3D printing or the like, or main body 26 may beformed of multiple pieces that are joined together either in a removablemanner such as by screwing, bolting, friction fitting, snap fitting orthe like or joined in a permanent manner such as by gluing, adhering,welding or the like. In one arrangement, main body 26 is formed of arelatively rigid and durable plastic material, UHMW material, compositematerial, nylon material, fiber glass material or any other non-metallicmaterial, or combination thereof In an alternative arrangement, mainbody 26 is formed of one or more metallic materials. In anotherarrangement, main body 26 is formed of a combination metallic materialsand non-metallic materials. In one arrangement, main body 26 is formedof a non-metallic material with a metallic drill guide 40 inserted orformed within the main body 26.

In the arrangement shown, as one example, main body 26 includes a leftside 28, a right side 30, a forward end 32, a rearward end 34, a topside 36 and a bottom side or clamping surface 38. In the arrangementshown, as one example, left side 28 and right side 30 are generally flatand planar in shape and extend in a generally parallel planarrelationship to one another. Left side 28 and right side 30 connect attheir forward end to the outside edges of forward end 32. Left side 28and right side 30 connect at their rearward end to the outside edges ofrearward end 34. Left side 28 and right side 30 connect at their upperend to the outside edges of top side 36. Left side 28 and right side 30connect at their lower end to the outside edges of clamping surface 38.The planes of left side 28 and right side 30 extend in approximateperpendicular planar alignment to the planes formed by forward end 32and rearward end 34. The planes of left side 28 and right side 30 extendin approximate perpendicular planar alignment to the planes formed bytop side 36 and clamping surface 38.

In the arrangement shown, as one example, forward end 32 and rearwardend 34 are generally flat and planar in shape and extend in a generallyparallel planar relationship to one another. Forward end 32 and rearwardend 34 connect at their upper and lower ends to the top side 36 andclamping surface 38, respectively. Forward end 32 and rearward end 34connect at their sides to left side 28 and right side 30, respectively.The planes of forward end 32 and rearward end 34 extend in approximateperpendicular planar alignment to the planes formed by top side 36 andclamping surface 38. The planes of forward end 32 and rearward end 34extend in approximate perpendicular planar alignment to the planesformed by left side 28 and right side 30. In the arrangement shown, asone example, to ease drilling, the plane formed by the rearward end 34of main body 26 angles forward slightly as it extends upward fromclamping surface 38 to top side 36. In one arrangement, the angle therearward end 34 angles forward is approximate equal to the angle thatthe drill guide 40 extends through the main body 26 such that the planeof rearward end 34 extends in approximate perpendicular alignment to thecentral axis of rotation of the bore of drill guide 40. Or, said anotherway, the central axis of rotation of the bore of the drill guide 40extends through the plane of the rearward end 34 in an approximateperpendicular manner.

In the arrangement shown, as one example, top side 36 and clampingsurface 38 are generally flat and planar in shape and extend in agenerally parallel planar relationship to one another. Top side 36 andclamping surface 38 connect at their forward end to the upper and loweredges of forward end 32, respectively. Top side 36 and clamping surface38 connect at their rearward end to the upper and lower edges ofrearward end 34, respectively. Top side 36 and clamping surface 38connect at their outside edges to left side 28 and right side 30,respectively. The planes of top side 36 and clamping surface 38 extendin approximate perpendicular planar alignment to the planes formed byforward end 32 and rearward end 34. The planes of top side 36 andclamping surface 38 extend in approximate perpendicular planar alignmentto the planes formed by left side 28 and right side 30. Clamping surface38 is generally flat and planar so as to engage and lay flat on thesurface of a workpiece 116. Top side 36 extends in approximate parallelplanar relationship to clamping surface 38 so as to provide a flatsurface that receives the pad 118 of a clamp 120 that clamps the jigsegment 24 to a workpiece 116.

In this way, main body 26 is formed of a generally elongated square orrectangular shaped member.

Drill Guide: In the arrangement shown, as one example, main body 26includes a drill guide 40. Drill guide 40 may be formed of any suitablesize, shape and design and is configured to receive and guide drill bit102. While, main body 26 is shown as having only one drill guide 40, itis hereby contemplated that main body 26 may have any number of drillguides 40 such as two, three, four, five, six or more. In thearrangement shown, as one example, drill guide 40 is a generallycircular shaped member that is configured to receive and guide steppeddrill bit 102 through its bore and along its central axis. In onearrangement, drill guide 40 is formed of a metallic or hardened metallicmaterial so as to provide strength and durability as drill guide 40receives and guides stepped drill bit 102. Drill guide 40 may be moldedinto main body 26, screwed into main body 26, adhered to main body 26 ormechanically connected to main body 26 by any other manner, method ormeans.

In the arrangement shown, as one example, the axis of rotation of drillguide 40 that extends through the center of drill guide 40 extends at anacute angle. More specifically, in one arrangement, the angle betweenthe plane formed by clamping surface 38 and axis of rotation of drillguide 40 on the rearward side of the main body 26 is an acute angle,whereas the angle between the plane formed by clamping surface 38 andaxis of rotation of drill guide 40 on the forward side of the main body26 is an obtuse angle. In one arrangement, the acute angle is anywherebetween one degree and forty five degrees, or one degree and thirtydegrees, or one degree and twenty five degrees, or one degree and twentydegrees, or one degree and fifteen degrees, or between ten degrees andtwenty degrees, or between twelve degrees and eighteen degrees, and inone arrangement approximately fifteen degrees has been tested withsuccess. Approximately fifteen degrees is shown in the figures.

In the arrangement shown, as one example, drill guide 40 extends outwardfrom the plane formed by rearward end 34 a distance. By drill guide 40extending outward from rearward end 34 a distance this causes therearward end of drill guide 40 to form a stop surface that is configuredto engage the stop collar 110 of drill bit 102 thereby stopping theinward movement of drill bit 102 in an accurate and efficient manner.This rearward extension of drill guide 40 provides greater wearresistance as the metallic drill guide 40 engages the stop collar 110causing less wear, than if the stop collar 110 engaged the plastic orcomposite material of main body 26. In an alternative arrangement, thematerial of main body 26 engages the stop collar 110. In anotherarrangement, the rearward end of drill guide 40 is flush with the planeof rearward end 34 and as such the stop collar 110 engages the materialof main body 26 and drill guide 40 simultaneously. In anotherarrangement, the rearward end of drill guide 40 is recessed to aprotruding portion of material that forms main body 26 that extendsrearward of the plane of rearward end 34 and as such the stop collar 110engages the material of main body 26.

In one arrangement, the plane of rearward end 34 is perpendicular to theaxis of rotation of drill guide 40. In this arrangement, the plane ofrearward end 34 tilts slightly forward as it extends from clampingsurface 38 to top side 36.

In the arrangement shown, as one example, to accommodate the upwardextension of drill guide 40 as it extends rearward, the rearward portionof top side 36 angles upward in approximately parallel spaced alignmentto the axis of rotation of the drill guide 40. This upward angledportion of top side 36 of main body 26 allows the forward section ofmain body 26 to be vertically thinner (as compared to the rearwardsection of main body 26) while allowing the main body 26 to consume thedrill guide 40 at its rearward end despite the continued upwardextension of the drill guide at the rearward end of main body 26.

Opening: In the arrangement shown, as one example, main body 26 includesan opening 42. Opening 42 may be formed of any suitable size, shape anddesign and is configured to allow woodchips formed during drilling toexit the jig segment 24. In the arrangement shown, as one example,opening 42 is a generally rectangular shaped opening in the top side 36of main body 26 that extends downward into main body 26 and connects tothe opening or bore formed by drill guide 40. However, any other shapedopening is hereby contemplated for use as opening 42 as is any otherlocation on main body 26. In addition, while one opening 42 is shown foruse, any other number of openings 42 are hereby contemplated for usesuch as two, three, four, five, six or more. In the arrangement shown,opening 42 connects to the bore formed by drill guide 40. In thearrangement shown, as one example, opening 42 connects at the lowerforward end of drill guide 40 and in this way facilitates the exit ofwood chips from the main body 26.

Lock Feature & Receiver: In the arrangement shown, as one example, mainbody 26 includes at least one lock feature 44 and at least one receiver46. Lock feature 44 and receiver 46 are formed of any suitable size,shape and design and are configured to facilitate connection of aplurality of jig segments 24 (as well as spacers 48) together inside-to-side alignment either directly to one another or with one ormore spacers 48 positioned there between. Notably, lock features 44 andreceivers 46 are hereby contemplated for use connecting jig segments 24and/or spacers 48 to any other tool or device or object as well.

In the arrangement shown, as one example, lock feature 44 is formed as aunitary part of main body 26 and extends outward from main body 26 adistance. That is, lock feature 44 is shown formed as part of main body26 through molding, casting, machining or the like. However, it ishereby contemplated that lock feature 44 may be attached to or added tothe side of main body 26 by screwing, bolting, adhering, welding or byconnecting in any other manner. In the arrangement shown, as oneexample, lock feature 44 is positioned in a side of main body 26 betweenforward end 32 and rearward end 34 and extends outward in generallyperpendicular alignment to the plane formed by the side 28 of main body26. In the arrangement shown, as one example, lock feature 44 includes agenerally cylindrical post 122 that extends outward a distance from theside 28 of main body 50 a distance and connects at its outward end to afoot 124. In the arrangement shown, as one example, foot 124 is agenerally planar shaped member when viewed from forward end 32, rearwardend 34, top side 36 or clamping surface 38 and extends, in at least someplaces, beyond the exterior diameter of post 122 such that foot 124 islarger, when viewed from the side, than post 122. By foot 124 beinglarger than post 112 this facilitates locking to other components. Inthe arrangement shown, as one example, foot 124 is a generallyrectangular shaped member with a rounded upper end and lower end whenviewed from the side which extends a greater distance between top side36 and clamping surface 38 than it extends between forward end 32 andrearward end 34. In this way, lock feature 44 is formed of a smallerpost 122 that connects to a larger foot 124 at its outward end whichfacilitates locking of lock feature 44 into receiver 46.

In the arrangement shown, as one example, receiver 46 is formed as aunitary part of main body 26 and extends inward into main body 26 adistance. In this arrangement, receiver 46 is positioned in a side ofmain body 26 between forward end 32 and rearward end 34, on a sideopposite receiver 44. In the arrangement shown, as one example, receiver46 includes an opening that is sized and shaped to receive foot 124 in aparticular orientation. In the arrangement shown, as one example, whenfoot 124 is formed of a generally rectangular shaped member with arounded upper end and lower end, the opening of receiver 46 is similarlyshaped to allow the insertion of foot 124 therein. In this way, foot 124may be inserted into the opening of receiver 36 with close and tighttolerances.

However, in the arrangement shown, as one example, foot 124 of lockfeature 44 is vertically aligned, meaning that it is longer between topside 36 and clamping surface 38, whereas the opening of receiver 46 islonger between forward end 32 and rearward end 34 than it is between topside 36 and clamping surface 38. Said another way, the opening ofreceiver 46 is oriented ninety degrees to the orientation of foot 124 oflock feature 44. However, any other angle of orientation is herebycontemplated for use.

In this arrangement, to assemble two jig segments 24 together, or a jigsegment 24 to a spacer 48, the two jig segments 24 are held inside-to-side alignment to one another and are rotated ninety degrees toone another so as to align the foot 124 of one jig segment 24 to theopening in the receiver 46 of the other jig segment 24. Once aligned inthis manner, the foot 124 of one jig segment 24 is inserted into theopening of the receiver 46 of the other jig segment 24. Once the foot124 is inserted into the receiver 46, the two jig segments 24 are thenrotated ninety degrees to one another. In doing so, the foot 124perpendicularly aligns to the opening of the receiver 46 thereby lockingthe two jig segments 24 together. That is, because the opening in thereceiver 46 is horizontally longer than it is vertically tall, whereasthe foot 124 is vertically taller than it is horizontally long, when thetwo jig segments 24 are rotated after the foot 124 is inserted withinthe receiver 46 the upper and lower edges of foot 124 that extends pastthe exterior diameter of post 122 extend past the edges of the openingof the receiver 46. That is, the upper and lower edges of foot 124 thatextends past the exterior diameter of post 122 extend past the edges ofthe opening of the receiver 46 and are captured behind a layer ofmaterial of the main body 26 of the connected jig segment 24 or spacer48. In this way, the foot 124 of one jig segment 24 cannot laterallypull out of the receiver 46 of the other jig segment 24. That is, thetwo jig segments 24 cannot laterally move away from one another. Infact, as more force is applied pulling adjacent jig segments 24 awayfrom one another more force is applied pulling the interior surface offoot 124 of one jig segment 24 or spacer 48 into the interior surfaceadjacent the opening of receiver 46 of the adjacent jig segment 24 orspacer 28 thereby strengthening the connection between the twocomponents. In one arrangement, to facilitate a stronger connection, aninterior portion of the receiver 46, that receives foot 124, includes astop feature, detent, cam surface or other feature that engages theupper and/or lower edges of the foot 124 or any other portion of foot124 upon full rotation or full installation thereby locking the twocomponents in a fully assembled and aligned state and helping tofrictionally hold the two components in this fully assembled and fullyrotated state by imparting a frictional force upon the foot 124. Thisarrangement may also provide a frictional feedback to the user toindicate the fully assembled state.

To separate the two jig segments 24, the two jig segments 24 are simplyrotated in the opposite direction, until the periphery of foot 124 isaligned with the opening 42 and once aligned the foot 124 is simplylaterally pulled through the opening 42 thereby separating the two jigsegments 24 and/or spacers 48.

In one arrangement, to further hold two jig segments 24 together in afully aligned state, as well as to indicate to the user that the two jigsegments 24 are fully assembled and aligned with one another, one sideof jig segment 24 includes one or more protrusions 126 and the other oropposite side includes one or more recesses 128. When two jig segments24 are connected together in side-to-side alignment and are rotated intofull locking engagement with one another, the protrusions 126 of one jigsegment 24 are received within the recesses 128 of the other jig segment24. In this way, the engagement of protrusions 126 and recesses 128 helpto hold jig segments 24 in a fully locked and aligned state.

In one arrangement, (as is shown in FIGS. 1-10) , as one example, jigsegments 24 include a pair of protrusions 126 in one side of main body26 with one protrusion 126 positioned forward of lock feature 44 andanother protrusion 126 positioned rearward of lock feature 44. In onearrangement, protrusions 126 are small rounded or spherical members thatextend outward of from the side of main body 26. In one arrangement, (asis shown in FIG. 5) recesses 128 include a recess in the side of mainbody 26, on a side opposite protrusion 126 and aligned with protrusion126. In this arrangement, recess 128 includes a vertically alignedgroove that extends from the top side 36 to the clamping surface 38 ofmain body 26 and includes a pair of bars 130 positioned within therecess 128. As the jig segments 24 are rotated into alignment with oneanother, the protrusion 126 of one jig segment 24 is received within therecess 128 of the other jig segment 24. As the two jig segments 24 arealmost fully rotated into planar alignment with one another, theprotrusion 126 of one jig segment 24 engages a bar 130 within the recess128 of the other jig segment 24. Once enough pressure is applied, theprotrusion 128 moves over the bar 130 and is held or captured within thelow spot between the two bars 130. In this position, the two jigsegments 24 are fully aligned with one another, meaning that the topside 36 and clamping surface 38 are aligned with one another tofacilitate clamping onto a workpiece 116. In this position, additionalforce must be applied to force the protrusion 126 out of the low spotbetween the bars 130 which helps to hold the jig system 10 in a fullyassembled position. By using two bars 130, the two jig segments 24positioned within grooves that extend the entire vertical length of thejig segments 24 may be rotated either way, clockwise orcounterclockwise, to assemble or disassemble the two jig segments 24.This increases the versatility of the jig segments 24 as well asincreases the ease of use.

In one arrangement, when the protrusions 126 of one jig segment 24 areheld within the recesses 128 between bars 130 of an adjacent jig segment24 there is contact and pressure pushing the opposing jig segments 24away from one another. This engagement and pressure helps to form asecure connection between the lock feature 44 of one jig segment 24 andthe receiver 46 of the other jig segment 24 thereby forming a strong andstable connection between opposing jig segments 24. This connectionforms a frictional engagement between adjacent jig segments 24 thathelps to hold the position of adjacent jig segments 24 in a unified andaligned manner. This engagement also provides a firm and rigid feelingsystem 10 that does not have any wobble, rattling, give or relativemovement among the individual components of the system 10. In addition,this engagement also provides alignment between the individualcomponents of the system 10 thereby ensuring that all components form aplanar top surface and planar bottom surface that extends across allcomponents of the system 10.

In another arrangement, (as is shown in FIG. 11) jig segments 24 includea pair of protrusions 126, with one protrusion 126 positioned at theintersection of a sidewall and the top side 36 on one side of the lockfeature 44, and another protrusion 126 positioned at the intersection ofa sidewall and the clamping surface 38 on the other side of the lockfeature 44. In the arrangement shown, as one example, the upperprotrusion 126 is positioned forward of the lock feature 44 and thelower protrusion 126 is positioned rearward of the lock feature 44,however the opposite arrangement is also contemplated for use, as is theuse of a plurality of protrusions 126 on the forward and/or rearwardsides of the lock feature 44. Similarly, in this arrangement, jigsegments 24 include a pair of recesses 128, with one recess 128positioned at the intersection of a sidewall and the top side 36 on oneside of the lock feature 44 and another recess 128 positioned at theintersection of a sidewall and the clamping surface 38 on the other sideof the lock feature 44. In the arrangement shown, as one example, therecesses 128 is positioned forward of the lock feature 44 and therecesses 128 is positioned rearward of the lock feature 44, however theopposite arrangement is also contemplated for use, as is the use of aplurality of recesses 128 on the forward and/or rearward sides of thelock feature 44. In the arrangement shown, as one example, theseprotrusions 126 and recesses 128 are generally triangular in shape orrounded in shape when viewed from the side, however any other shape ishereby contemplated for use. In this arrangement, as the two jigsegments 24 rotated into planar alignment with one another, theprotrusions 126 of one jig segment 24 engages the recesses 128 of theother jig segment 24. The engagement of the protrusion 126 with theedges of the recess 128 stop the two jig segments 24 in a fully alignedposition thereby preventing over rotation. Once enough pressure isapplied, the protrusions 126 move into and are frictionally held withinthe recesses 128 of the other jig segment 24 and are frictionally heldin place due to frictional engagement between opposing jig segments 24.In one arrangement protrusions 126 include a lip that fits behind aflange in recesses 128 thereby preventing the two jig segments frompulling apart from one another when fully assembled. In anotherarrangement protrusions 126 are over-sized and engage recesses 128 in amanner that force the two jig segments 24 away from one another therebytightening the connection between receiver 46 and lock feature 44 ofopposing jig segments 24 thereby helping to hold the two jig segments 24in a fully assembled and aligned position, this may include adetent-engagement arrangement and/or a friction-fit-engagementarrangement. In this fully assembled position, the two jig segments 24are fully aligned with one another. In this position, additional forcemust be applied to force the protrusions 126 out of the recesses 128 dueto the frictional engagement. In an alternative arrangement, only oneprotrusion 126 and recess 128 may be present, either forward of orrearward of lock feature 44. In another alternative arrangement, morethan one protrusion 126 and recess 128 may be present, either forward ofor rearward of lock feature 44, such as two, three, four, five, six ormore.

In another arrangement, (as is shown in FIG. 15), jig segments 24include a pair of receivers 46 that include a key hole shaped memberthat forms receiver 46. In the arrangement shown, as one example, a pairof receivers 46 are placed in a side of the main body 26, one toward theforward end 32 of the main body 26 and one toward the rearward end 34 ofthe main body 26, however any number of receivers 46 are herebycontemplated for use. That is, the receivers 46 include an openinghaving a first section 132, a second section 134 and a waist 136. Inthis arrangement, the first section 132 is larger than the secondsection 134 and is configured to receive the foot 124 of lock feature 44therein with close and tight tolerances so as to allow insertion of foot124 into receiver 46. Second section 134 is smaller than first section132 and is large enough to receive post 122 therein but is smaller thanfoot 124 and as such foot 124 is retained by this portion of receiver 46which prevents lateral pull-out of the foot 124. Waist 136 is narrowerthan both first section 132 and second section 134 and is configured toallow the passage of post 122 from one of the first section 132 and thesecond section 134 to the other of the first section 132 and the secondsection 134, but as the post 122 moves through waist 136 the waist 136applies frictional force to the post 122 thereby requiring force to movethe post 122 from one of the first section 132 and the second section134 to the other of the first section 132 and the second section 134. Inthis way, the friction imparted upon post 122 by waist 136 helps to holdthe two jig segments 24 in a locked position as additional force must beapplied to unlock the two jig segments 24 once locked.

In this arrangement, the foot 124 of one jig segment 24 is configured tobe inserted within the first section 132 of the receiver 46 of the otherjig segment 24. Once the foot 124 is inserted within the first section134, the two jig segments 24 are moved with respect to one another suchthat the foot 124 moves from the first section 132 to the second section134. In the arrangement show, this movement is lateral or along theforward-to-back length of jig segments 24. In doing so, sufficient forcemust be applied when the waist 136 frictionally engages the post 122.Once sufficient force is applied and the post 122 passes waist 136, thefoot 124 is held within second section 134 and as the opening of secondsection 134 is smaller than the foot 124, the jig segments 24 cannot belaterally pulled apart, and therefor they are locked together. Todisassemble the two jig segments 24, the jig segments 24 are slid in anopposite direction and the opposite process is performed. In this way,the two jig segments 24 can be quickly and easily assembled anddisassembled in side-to-side locking alignment.

In another arrangement, (as is shown in FIG. 17), the lock feature 44and receiver 46 take the form of a dove-tail arrangement or otherlocking rail and groove arrangement. That is, in the arrangement shown,as one example, one side of jig segments 24 include lock feature 44 thatextends outward from one side of the main body 26 a distance. In thisarrangement, the outward portion of lock feature 44 is wider than theinward portion of lock feature 44. In one arrangement, as is shown, theoutward face of lock feature 44 is generally planar in shape and extendsin parallel spaced alignment to the plane formed by the side of mainbody 26 and the walls that connect to the outward planar face of thelock feature 44 extend at an angle inward as they extend toward mainbody 26 of jig segment 24. This is known as a dove tail feature. In thisarrangement, the receiver 46 has a similar, but opposite, shape. Thatis, as is shown, the inner face of receiver 46 is generally planar inshape and extends in parallel spaced alignment to the plane formed bythe side of main body 26 and the walls that connect to the inner planarface of the receiver extend at an angle. In this arrangement, the lockfeature 44 and receiver 46 extend a length of the side of the main body26 and the receiver opens to the forward end 32 of the main body 26. Inthis arrangement, two jig segments 24 are connected together by aligningthe two jig segments 24 in side-to-side alignment, and inserting theforward end of the lock feature 44 of one jig segment 24 into therearward end of the receiver 46 of the other jig segment 24. The jigsegments 24 are then slid with respect to one another until the forwardend of the lock feature 44 engages the forward end of the receiver 46 atwhich point the two jig segments 24 are fully assembled and aligned.This full insertion may be accompanied by a detent-engagementarrangement and/or a friction-fit-engagement arrangement that helps holdthe two jig segments 24 together in locking engagement with one anotherat the point of full assembly. In this position, due to the lock feature44 being wider at its outward side than at its inward side, theengagement of the lock feature 44 within the receiver 46 prevents thetwo jig segments 24 from being laterally pulled apart. While only asingle dovetail feature lock feature 44 and only a single dovetailfeature receiver 46 is presented in this arrangement it is herebycontemplated that multiple dovetail feature lock features 44 andmultiple dovetail feature receivers 46 may be used in association withthe connection of adjacent jig segments 24 and/or spacers 48. Thesemultiple dovetail feature lock features 44 and multiple dovetail featurereceivers 46 may be vertically stacked with respect to one another, suchas one above the other. These multiple dovetail feature lock features 44and multiple dovetail feature receivers 46 may be laterally aligned withrespect to one another, such as one at the forward end and one at therearward end. A combination of laterally stacked and laterallypositioned dovetail features is also contemplated as well.

Any other arrangement of connecting two adjacent jig segments 24 and/orspacers 48 is hereby contemplated for use, as is any combination ofmanners or methods presented herein.

Grip Material: In one arrangement, jig segments 24 include a layer ofgrip material on the clamping surface 38 of jig segment 24 (as well asthe clamping surface 62 of spacer 48). That is, in use the clampingsurface 38 engages the surface of a workpiece 116. It is highlydesirable that once the jig segment 24 is placed in position on theworkpiece 116 and clamped in place that the jig segment 24 does not moveduring a drilling operation. If the jig segment 24 moves during adrilling operation this can ruin the pocket hole and/or the workpiece116 as well as cause injury. As such, it is important that the jigsegment 24 not move after clamping. However, the small size of system10, which correlates with a small surface area of contact between system10 and workpiece 116 makes it difficult to firmly hold the jig system 10in place.

To provide maximum durability and strength and rigidity and ruggedness,the main body 26 of jig segment 24 is formed of a hard material such asa plastic material, composite material, a nylon material, a fiber glassmaterial or any other non-metallic material, or combination thereof.Alternatively, a metallic material is used which has superb hardness,but a low coefficient of friction. Alternatively, a combination ormetallic material and non-metallic material is used. While hardmaterials are good for durability, strength, rigidity and ruggedness,hard materials tend to have a low coefficient of friction. That is, hardmaterials tend to slide easily when placed on a surface or other object.The easier the jig segment 24 slides when placed on workpiece 116, themore pressure must be applied to keep the jig segment 24 in place duringdrilling. To correct this problem, a layer of grip material is placed onthe clamping surface 38. This grip material has a higher coefficient offriction than the material that forms the main body 26. Coefficient offriction describes the ratio of the force of friction between two bodiesand the force pressing them together. The higher the coefficient offriction, the more force is required to cause the two bodies to slidewith respect to one another. One drawback to using a material that has ahigh coefficient of friction, such as a compressible rubber or compositematerial, is that the higher the coefficient of friction theless-durable the material tends to be. As such, by forming the main body26 of a harder material that is strong and durable (but has a lowercoefficient of friction) and placing a grip material on the clampingsurface 38 that has a higher coefficient of friction is the best of bothworlds in that this provides a jig segment 24 that is hard and durablewhile also having a high coefficient of friction. By adding the griplayer on the clamping surface 38 this allows a user to apply lessclamping pressure with less risk of the jig segment 24 moving. Or, saidanother way, the user may apply the same clamping pressure to jigsegment 24 while producing a greater level of grip. This allows the useof conventional bar clamps, which apply less pressure than face clamps,and are more-commonly owned by do-it-yourselfers than face clamps.

Grip material may be attached to main body 26 any manner, method ormeans. In one arrangement, grip material is adhered to the clampingsurface 38 of main body 26. In another arrangement, grip material ismolded into or onto the clamping surface 38 of main body 26 in adual-molding or dual durometer molding manner. Grip material may besprayed onto or deposited onto the clamping surface. Grip material maybe added to main body 26 by any other manner, method or means. This gripmaterial may cover all of the clamping surface 38 of the jig segment 24,as is shown in FIG. 2. This grip material may cover all but the exteriorperipheral edge of the clamping surface 24, as is shown in FIG. 5. Thisgrip material may cover strips of the clamping surface 38, as is shownin FIG. 6. This grip material may be flush with the bottom surface ofjig segment 24. Alternatively, this grip material may protrude below thebottom surface of jig segment 24 to ensure first contact with workpiece116 before compression by a clamp 120. Any other arrangement is herebycontemplated for use.

Connector: The forward end 32 of main body 26 includes a connector 138.Connector 138 is formed of any suitable size, shape and design and isconfigured to facilitate the connection of tail section 68 to main body26. In the arrangement shown, as one example, connector 138 is formed ofa protrusion that extends forward from the forward end 32 of main body26 a distance and is slightly smaller than the periphery of main body26. In the arrangement shown, as one example, wherein the forward end 32of main body 26 is square in shape, connector 138 is similarly squareshaped. In this arrangement, connector 138 is slightly smaller in sizeand shape and extends perpendicularly out of the plane of forward end 32and terminates in a flat planer face at its forward end that extends inapproximate parallel spaced alignment to the plane formed by the forwardend 32 of main body 26. In this arrangement, as one example, a groove140 is positioned along the sides of connector 138 that extends from thetop side of connector 138 to the bottom side of connector 138. Groove140 may also be present in the top side of the connector 138 and extendacross the width of connector 138 from side-to-side. Connector 138 andits grooves 140 are configured to receive the rearward end of tailsection 68 thereon. In this way, the presence of groove 140 in connector138 forms a flange or lip at the forward end 32 of jig segment 24 thatis received and/or held onto by the rearward end of tail section 68.

Spacer: Spacers 48 are formed of any suitable size, shape and design andare configured to connect between two jig segments 24 so as to positionadjacent jig segments at desired spacing from one another to form apocket hole jig 10 comprised of multiple jig segments 24 at variousspacing. As spacers 48 are configured to connect to jig segments 24, inone arrangement spacers 48 are largely formed in the same size, shapeand configuration as jig segments 24 without drill guide 40 and withoutthe attachment of a tail section 68 thereto. As such, unless statedspecifically otherwise, the disclosure provided herein with respect tothe size, shape and configuration of segments 24 is hereby repeated forspacers 48, except for the connection of tail sections 68 and the use ofdrill guides 40.

That is, the arrangement shown, as one example, spacer 48 includes amain body 50. Main body 50 is formed of any suitable size, shape anddesign and is configured to be the main structural member of spacer 48.Main body 50 may be formed of a single monolithic and unitary piece thatis formed by molding, machining, 3D printing or the like, or main body50 may be formed of multiple pieces that are joined together either in aremovable manner such as by screwing, bolting, friction fitting, snapfitting or the like or joined in a permanent manner such as by gluing,adhering, welding or the like. In one arrangement, main body 50 isformed of a plastic material, composite, nylon, fiber glass or othernon-metallic material, or combination thereof. Alternatively, a metallicmaterial is used which has superb hardness, but a low coefficient offriction. Alternatively, a combination or metallic material andnon-metallic material is used.

In the arrangement shown, as one example, main body 50 includes a leftside 52, a right side 54, a forward end 56, a rearward end 58, a topside 60 and a bottom side or clamping surface 62. In the arrangementshown, as one example, left side 52 and right side 54 are generally flatand planar in shape and extend in a generally parallel planarrelationship to one another. Left side 52 and right side 54 connect attheir forward end to the outside edges of forward end 56. Left side 52and right side 54 connect at their rearward end to the outside edges ofrearward end 58. Left side 52 and right side 54 connect at their upperend to the outside edges of top side 60. Left side 52 and right side 54connect at their lower end to the outside edges of clamping surface 62.The planes of left side 52 and right side 54 extend in approximateperpendicular planar alignment to the planes formed by forward end 56and rearward end 58. The planes of left side 52 and right side 54 extendin approximate perpendicular planar alignment to the planes formed bytop side 60 and clamping surface 62.

In the arrangement shown, as one example, forward end 56 and rearwardend 58 are generally flat and planar in shape and extend in a generallyparallel planar relationship to one another. Forward end 56 and rearwardend 58 connect at their upper and lower ends to the top side 60 andclamping surface 62. Forward end 56 and rearward end 58 connect at theirsides to left side 52 and right side 54. The planes of forward end 56and rearward end 58 extend in approximate perpendicular planar alignmentto the planes formed by top side 60 and clamping surface 62. The planesof forward end 56 and rearward end 58 extend in approximateperpendicular planar alignment to the planes formed by left side 52 andright side 54.

In the arrangement shown, as one example, top side 60 and clampingsurface 62 are generally flat and planar in shape and extend in agenerally parallel planar relationship to one another. Top side 60 andclamping surface 62 connect at their forward end to the upper and loweredges of forward end 56. Top side 60 and clamping surface 62 connect attheir rearward end to the upper and lower edges of rearward end 58. Topside 60 and clamping surface 62 connect at their outside edges to leftside 52 and right side 54. The planes of top side 60 and clampingsurface 62 extend in approximate perpendicular planar alignment to theplanes formed by forward end 56 and rearward end 58. The planes of topside 60 and clamping surface 62 extend in approximate perpendicularplanar alignment to the planes formed by left side 52 and right side 54.Clamping surface 62 is generally flat and planar so as to engage and layflat on the surface of a workpiece 116. Top side 60 extends inapproximate parallel planar relationship to clamping surface 62 so as toprovide a flat surface that receives the pad 118 of a clamp 120 thatclamps the spacer 68 to a workpiece 116.

In this way, main body 50 is formed of a generally elongated square orrectangular shaped member. In one arrangement, the rearward end 58 ofmain body 50 of spacer 48 tilts slightly forward as it extends fromclamping surface 62 to top side 60, so as to mimic the size and shape ofthe main body 26 of jig segments 24. Similarly, in one arrangement, therearward end of the top side 60 extends upward, similar to the rearwardend of the top side 36 of jig segments 24, so as to mimic the size andshape of the main body 26 of jig segments 24. In an alternativearrangement, the upward extension at rearward end of top side is notpresent as this upward extension is not needed as there is no drillguide 40 in spacer 48. Alternatively, in other arrangements, a drillguide 40 is present in spacer 48 but no tail section 68 is connected tospacer 48. In an alternative arrangement a tail section 68 is connectedto spacer 48.

Lock Feature & Receiver: In the arrangement shown, main body 50 ofspacers 48 includes a lock feature 44 and a receiver 56. Lock feature 44and receiver 46 are formed of any suitable size, shape and design andare configured to facilitate connection to the lock feature 44 andreceiver 46 of jig segments 24. In this way, a pocket hole jig system 10may be formed of a pair of jig segments 24 connected together inside-to-side alignment with one or more spacers 48 positioned betweenthe jig segments 24.

As the lock features 44 and receivers 46 of spacers 48 and jig segments24 are configured to connect together to one another in a matingarrangement, the lock features 44 and receivers 46 of spacers 48 and jigsegments 24 are similar if not identical to one another. As such, thedisclosure provided herein with respect to the lock features 44 andreceivers 46 of jig segments 24 is hereby repeated for spacers 48. Assuch, spacers 48 connect in side-to-side alignment to with jig segments24 in the same way described herein with respect to connecting jigsegments 24 in side-to-side alignment. To facilitate various spacing ofjig segments 24, spacers 48 may be formed of any width, from narrow towide. Narrow spacers 48 may be as narrow as ¼ of an inch, or ⅓ of aninch or ½ of an inch, or any other width. Wide spacers 48 may be as wideas an inch or more.

Spacer-To-Spacer Connection: To be clear, in some applications it may bedesirable to connect two or more spacers 48 to one another inside-to-side alignment to as to set the optimum spacing between adjacentjig segments 24. As the sides of jig segments 24 and spacers 48 areessentially identical, any number of jig segments 24 and spacers 48 maybe connected in side-to-side alignment in any arrangement. As oneexample, in the arrangement, wherein a 2×6 board is being used and thejig segments 24 and spacers 48 are one inch wide, it may be desirable tohave a pair of jig segments 24 connected to a pair of spacers 48positioned between the jig segments 24. This arrangement results in jig10 that is four inches wide in overall width that positions the centerof two pocket holes three inches apart (which, if centered on the2×6—which is only 5.5 inches wide—places the center of each pocket hole1.25 inches inward from the outward edges of the 2×6) which may provideoptimum results. Any number of spacers 48, of any width, may beconnected in side-to-side alignment to attain the optimum spacingbetween jig segments 24.

Tail Section: Tail sections 68 are formed of any suitable size, shapeand design and are configured to connect to the forward end 32 of jigsegments 24 and/or spacers 48 and serve to facilitate the placement ofthe jig segment 24 at the desired distance from the edge of a workpiece116. In the arrangement shown, as one example, tail section 68 includesa main body 70. Main body 70 is formed of any suitable size, shape anddesign and is configured to be the main structural member of tailsection 68. Main body 70 may be formed of a single monolithic andunitary piece that is formed by molding, machining, 3D printing or thelike, or main body 50 may be formed of multiple pieces that are joinedtogether either in a removable manner such as by screwing, bolting,friction fitting, snap fitting or the like or joined in a permanentmanner such as by gluing, adhering, welding or the like. In onearrangement, main body 70 is formed of a plastic material, composite,nylon, fiber glass or other non-metallic material, or combinationthereof. Alternatively, a metallic material is used which has superbhardness, but a low coefficient of friction. Alternatively, acombination or metallic material and non-metallic material is used.

In the arrangement shown, as one example, main body 70 includes a leftside 72, a right side 74, a forward end 76, a rearward end 78, a topside 80 and a bottom side or clamping surface 82. In the arrangementshown, as one example, left side 72 and right side 74 are generally flatand planar in shape and extend in a generally parallel planarrelationship to one another. Left side 72 and right side 74 connect attheir forward end to the outside edges of forward end 76. Left side 72and right side 74 connect at their rearward end to the outside edges ofrearward end 78. Left side 72 and right side 74 connect at their upperend to the outside edges of top side 80. Left side 72 and right side 74connect at their lower end to the outside edges of clamping surface 82.The planes of left side 72 and right side 74 extend in approximateperpendicular planar alignment to the planes formed by forward end 76and rearward end 78. The planes of left side 72 and right side 74 extendin approximate perpendicular planar alignment to the planes formed bytop side 80 and clamping surface 82.

In the arrangement shown, as one example, forward end 76 and rearwardend 78 are generally flat and planar in shape and extend in a generallyparallel planar relationship to one another. Forward end 76 and rearwardend 78 connect at their upper and lower ends to the top side 80 andclamping surface 82, respectively. Forward end 76 and rearward end 78connect at their sides to left side 72 and right side 74, respectively.The planes of forward end 76 and rearward end 78 extend in approximateperpendicular planar alignment to the planes formed by top side 80 andclamping surface 82. The planes of forward end 76 and rearward end 78extend in approximate perpendicular planar alignment to the planesformed by left side 72 and right side 74.

In the arrangement shown, as one example, top side 80 and clampingsurface 82 are generally flat and planar in shape and extend in agenerally parallel planar relationship to one another. Top side 80 andclamping surface 82 connect at their forward end to the upper and loweredges of forward end 76, respectively. Top side 80 and clamping surface82 connect at their rearward end to the upper and lower edges ofrearward end 78, respectively. Top side 80 and clamping surface 82connect at their outside edges to left side 72 and right side 74,respectively. The planes of top side 80 and clamping surface 82 extendin approximate perpendicular planar alignment to the planes formed byforward end 76 and rearward end 78. The planes of top side 80 andclamping surface 82 extend in approximate perpendicular planar alignmentto the planes formed by left side 72 and right side 74. Clamping surface82 is generally flat and planar so as to engage and lay flat on thesurface of a workpiece 116. Top side 80 extends in approximate parallelplanar relationship to clamping surface 82 so as to provide a flatsurface that receives the pad 118 of a clamp 120 that clamps the tailsection 68 to a workpiece 116, however in some arrangements it may bemore desirable to clamp on top of the main body 26 of jig segments 24and the main body 50 of spacer 48.

Tail section 68 is configured to connect in a removable manner to theforward end 32 of main body 26 of jig segments 24. By tail section 68being removable allows the jig segments 24 to be used on inside cornerswhen the tail section 68 is removed, and also allows the jig segments 24to be used on the edge of workpieces 116 when the tail section 68 is inplace. Tail section 68 is configured to be quickly and easily and in asecure manner connected to the forward end 32 of main body 26 of jigsegment 24 by sliding over the connector 138 and connecting to connector138 in frictional locking engagement. In one arrangement, as oneexample, to facilitate this connection, the rearward end 78 of tailsection 68 includes an opening 142 that is configured to fit over andengage and receive connector 138 in locking frictional engagement. Inone arrangement, as is shown, opening 142, when viewed from the rearwardside of tail section 68 is generally square in shape and has a size andshape that is configured to receive the connector 138 therein. In thisarrangement, the lower end of opening 142 is open at its bottom sidesuch that the tail section 68 may slide over the connector 138 of mainbody 26. In the arrangement shown, to facilitate locking engagement, theopening 142 includes a flange 144 that extends inward along the sides ofopening 142 and is configured to be received within the groove 140 ofconnector 138. In the arrangement, where connector 138 includes a groove140 along its top surface, a flange 144 is positioned along the top sideof the opening 142 that is configured fit within this portion of thegroove 140. In one arrangement, as is shown in FIG. 4, small protrusions146 are positioned at the lower end of flange 144 and extend inward adistance. The purpose of these protrusions 146 are configured to providean increased amount of resistance upon insertion of connector 138 intoopening 142 as well as to help hold the tail section 68 onto theconnector 138 when in place. That is, when tail section 68 is fullyinstalled over the connector 138, these protrusions 146 fit around thelower end of connector 138 with frictional and locking engagementthereby helping to hold tail section 68 onto jig segment 24.

To attach tail section 68 to main body 26 of jig segment 14, the tailsection 68 is positioned above the jig segment 14 and the opening 142 oftail section 68 is aligned with the connector 138 of jig segment 14. Indoing so, the plane of the rearward end 78 of tail section 68 is alignedwith the plane of the forward end 32 of jig segment 14. In thisposition, the flange 144 of opening 142 is aligned with the groove 140of connector 138. Once aligned, the jig segment 24 and tail section 68are moved toward one another until the protrusions 146 positioned at thelower end of flange 144 engage the connector 138. As force is appliedthat overcomes the frictional engagement between protrusions 146 andconnector 138, the tail section 68 slightly deforms to allow connector138 to fit within opening 142. As the tail section 68 slides downward onjig segment 24, the flange 144 of opening 142 fits within the groove 140of connector 138. This continues until the top of opening 142 engagesthe top of connector 138 and at this fully assembled position, theprotrusions 146 at the lower end of flange 144 move past the lower endof connector 138 and move inward toward one another around the lower endof connector 138 thereby holding the tail section 68 onto the connector138. In this position, the flange 144 of opening 142 is seated withinthe groove 140 of connector 138 and the rearward end 78 of tail section68 is in planar engagement and alignment with the forward end 32 of jigsegment 24. In this way, the connector 138 of jig segment 24 and opening142 of tail section 68 cooperate to quickly, easily and in a securemanner connect jig segment 24 and tail section 68.

To remove tail section 68 from jig segment 24, tail section 68 is movedupward with respect to jig segment 24. Sufficient force is applied tocause the protrusions 146 in the lower end of flange 144 to move aroundconnector 138. Once sufficient force is applied to cause the protrusions146 in the lower end of flange 144 to move around connector 138, thetail section 68 is slid upward until the two components are free of oneanother.

Stop Feature: Tail section 68 includes a stop feature 90. Stop feature90 is formed of any suitable size, shape and design and is configured tofacilitate the placement of the jig segment 24 at the desired distancefrom an edge of a workpiece 116 based on the thickness of the workpiece116. In one arrangement, as is shown, stop feature 90 fits within thehollow interior 84 of tail section 68 and slides a distance between theforward end 76 of main body 70 and the rearward end 78 of main body 70.To facilitate this sliding engagement, stop feature 90 is spring biasedand includes at least one arm 148 on each side of the stop feature 90that fits within a slot 86 in tail section 68 that extends a distancebetween the forward end 76 of main body 70 and the rearward end 78 ofmain body 70. In one arrangement, as is shown, stop feature 90 includesan arm 148 positioned at the forward end of the stop feature 90 and anarm 148 positioned at the rearward end of the stop feature 90, both ofwhich are received within slot 86. The use of two arms 148 help toprovide stability and alignment to stop feature 90 relative to tailsection 68. In addition, the use of two arms 148 helps to lock bothsides of stop feature 90 in place when they are received within stops 88thereby ensuring the stop feature 90 remains in place when set. Thisslot 86 includes a plurality of stops 88 therein that are configured toreceive the forward positioned arms 148 when the stop feature 90 ispositioned at various common thicknesses of workpieces 116. In onearrangement, these stops 90 are positioned at ½ inch, ¾ inch and 1½ inchpositions, however any other common thickness is hereby contemplated foruse.

In one arrangement, as is shown, stop feature 90, when viewed from theside, is generally formed in a U-shape, with an upper section that ridesalong the interior surface of the top side 80 of tail section, a lowersection that rides along the interior surface of clamping surface 82,and a center section that connects the upper section and lower sectionof stop feature 90. In one arrangement, this U-shaped stop feature 90 isspring biased outward. Or, said another way, when the stop feature 90 ispositioned within the hollow interior 84 of tail section 68 the uppersection and lower section have an outward force. This outward forceforces the arms 148 positioned at the forward end of stop feature 90into the stops 88 positioned in the lower surface of slot 86. It is thisspring bias that maintains the stop feature 90 at its desired positionwhen the rearward arms 148 are received within a set of stops 88 in slot86.

A rearward flange 150 extends downward from stop feature 90 adjacent itsrearward end. Rearward flange 150 is configured to provide a stopsurface on its rearward side that engages an edge of a workpiece 116. Assuch, in one arrangement, rearward flange 150 extends generallyperpendicularly below the clamping surface or lower surface of tailsection 68 a distance so as to provide a flat surface upon which toengage an edge of the workpiece 116. A forward flange 152 extendsdownward from stop feature 90 adjacent its rearward end. Forward flange152 is configured to provide a grip surface for a user to adjust theposition of the stop feature 90 within the tail section 68. Forwardflange 152 is positioned below forward positioned arms 148 and allowsthe user to easily push up on or adjacent the forward flange 152 therebymoving the forward positioned arms 148 out of the stops 88 of slot 86thereby allowing the stop feature 90 to be slid along slot 86 withintail section 68. As the forward flange 152 is pushed upward, the springbias of stop feature 90 is overcome thereby allowing the forward arms148 to be moved upward and out of stops 88 in slot 86 thereby allowingadjustment of the position of stop feature 90.

Tail section 68 includes a plurality of openings 92 in the top side 80of main body 70 that provides visibility to the position of the stopfeature 90 within the tail section 68. That is, when the stop feature 90is visible through one of the openings 92 in tail section 68 that is thethickness of the workpiece 116 that the stop feature 90 is set for. Inone arrangement, as is shown, these openings 92 are circular in shape,however any other shape is hereby contemplated for use such as oval,rectangular, triangular, square or any other shape. Also, in onearrangement, as is shown, indicia 154 is positioned adjacent eachopening 92. Indicia 154 indicates the thickness of the workpiece 116that the stop feature 90 is set for when the stop feature 90 is visiblethrough that particular opening 92. Indicia 154 may be writing orprinting on the tail section 68, etching into the material of tailsection 68, raised lettering or any other form of indicia or marking.

In this way, tail section 68 is easily attached to and removed from jigsegments 24 and the stop feature 90 is easily adjusted for varyingthicknesses of workpieces 116 and the setting is easily visible throughopenings 92.

Alternative Arrangement—Slots & Stop Feature:

In FIGS. 1-5, tail section 68 includes a slot 86 that extends a forwardto back length of tail section 68 and is positioned in the sides 72, 74of tail section 68. This slot 86 receives the arms 148 of stop feature90 and facilitates guidance of the stop feature 90 as it moves withintail section 68. This slot 86 also facilitates locking the stop feature90 in place at predetermined positions through engagement of arms 148into stops 88. While this arrangement is effective, due to the intendeduse of the jig system 10, the jig system 10 is clamped onto a workpiece116, a slot 86 that extends a length of the tail section 68 has atendency to weaken the sides 72, 74 of tail section 68 which can causecollapse or crushing of the tail section 68 if the tail section 68 isclamped with too much pressure.

To avoid crushing of the tail section 68, and to strengthen the sides72, 74 of the tail section 68, in an alternative arrangement, withreference to FIGS. 6-10, tail section 68 has solid sides 72, 74. In thisarrangement, stop feature 90 fits within the hollow interior 84 and arms148 fit within stops 88 positioned in the outward edges of the bottomside 81 of tail section 68. In this arrangement, the wall of the bottomside 82 extends inward slightly a distance and partially closes thelower end of the hollow interior 84 of tail section 68 and includesstops 88 therein, which, in one arrangement, as is shown, are recessesor notches or the like. This configuration and arrangement provides theability to position stop feature 90 at the desired workpiece thicknesssettings, while also not weakening the strength of sides 72, 74 of tailsection 68. Any other configuration of tail section 68 and/or sides 72,74 is hereby contemplated for use.

Workpiece Thickness Gauge: In one arrangement, system 10 includes aworkpiece thickness gauge 94. Workpiece thickness gauge 94 is formed ofany suitable size, shape and design and is configured to facilitatequick and easy and confident measuring of the thickness of workpiece 116so as to facilitate proper setting of the stop feature 90 of the tailsection 68 and the stop collar 110 on the stepped drill bit 102. In thearrangement shown, as one example, workpiece thickness gauge 94 includesa main body 96 that includes a plurality of steps 156 therein. Each step156 is configured to be associated with a common workpiece thickness,such that when a workpiece 116 fits within a step 156 the workpiecethickness gauge 94 provides a measurement of its thickness. In onearrangement, as is shown, the workpiece thickness gauge 94 includesindicia 98 associated with each step 156. This indicia 156 indicates thethickness of the workpiece 116. The user can then take this measurementand set the position of stop feature 90 of tail section 68 to theappropriate corresponding position. These distances or measurements orsteps 156 also correlate to common screw lengths, as such, each step 156has an assigned screw length. In this way, the use of the workpiecethickness gauge 94 takes a lot of the guesswork out of the where toposition the stop feature 90 and the stop collar 110 of the steppeddrill bit 102 when drilling pocket holes using system 10.

In one arrangement, workpiece thickness gauge 94 is a standalonecomponent. In another arrangement, the main body 96 of workpiecethickness gauge 94 is operatively connected to, molded onto, formed as asingle piece with, formed as part of, or formed around an Allen wrench100 which is used to adjust the position of the stop collar 110 of thestepped drill bit 102 by facilitating tightening and loosening of thefastener 114 of the stop collar 110. In this way, the combination of theworkpiece thickness gauge 94 with Allen wrench 100 improves efficienciesby combining two needed tools to use the system 10 into a single tool orcomponent thereby reducing the number of parts or pieces of the system10.

An alternative arrangement of workpiece thickness gauge 94 is presentedwith respect to FIGS. 25, 26 and 27. In this arrangement, main body 96is formed around or molded onto, or formed integral with Allen wrench100. In this arrangement, main body 96 follows the Allen wrench 100around the ninety degree bend a distance before terminating. In thisway, main body 96 forms a generally flat upper surface 158 that extendsin approximate perpendicular planar arrangement to a generally flatinterior surface 160. In use, an edge of a workpiece 116 is placed onthe upper surface 158 and on the side surface 160 and the indicia 98indicate the approximate thickness of workpiece 116. In the arrangementshown, the indicia 98 are positioned between a line on each side. Whenan edge of a workpiece 116 falls between the lines on each side of theindicia 98, the stop collar 110 is to be set to the indicia 98 and acorresponding screw length is to be used. To ensure that burrs or otheraberrations that are often present on the corner of a workpiece 116 donot interfere with accurate measurement, a recess 162 is positioned atthe intersection of upper surface 158 and side surface 160 that providesa relief for these burrs or other aberrations. Also present on main body96, adjacent side surface 160 is indicia 164 that indicate the edge of aworkpiece 116 is intended to be placed flush against the side surface160. In the arrangement shown, this indicia 164 takes on the form of aplurality of arrows, however any other design or configuration iscontemplated for use. A logo 166 is also shown in a side of main body 96that indicates the manufacturer of main body 96. Any other form, shapeor configuration of workpiece thickness 94 gauge is hereby contemplatedfor use.

With reference to FIGS. 98-108 an alternative configuration of aworkpiece thickness gauge 94 is presented that includes a main body 96having a plurality of indicia 98 thereon and a recess 162 that issimilar to the above-presented embodiments that is wrapped around anAllen wrench 100. This arrangement allows for measurement on either sideof the Allen wrench.

Drill Bit & Stop Collar: In one arrangement, system 10 includes a drillbit 102 having a stop collar 110 therein. Drill bit 102 and stop collar110 are formed of any suitable size, shape and design and is configuredto facilitate stepped pocket holes at the desired depth. In thearrangement shown, as one example, drill bit 102 extends a length from aconnection end 104 that is configured to receive the chuck of aconventional drill, and a drilling end 106, that is configured to drillinto workpiece 116. In one arrangement, drilling end 106 includes astepped feature, which is a smaller diameter section. The inclusion ofthe stepped feature in drill bit 102 is what forms the stepped pocketholes. The portion of the hole formed by the stepped feature receivesand provides alignment to the shank of a screw, whereas the largerdiameter portion of the hole receives the head of the screw.

Stop collar 110 is configured to be placed over the drill bit 102 at aposition between the connection end 104 and the drilling end 106. Thestop collar 110 is positioned by tightening a fastener 114, such as aconventional screw or bolt in the stop collar 110, against the drill bit102, such as using Allen wrench 100. The position of the stop collar 110affects the depth of the pocket hole. The optimum depth of the pockethole is dependent on the thickness of the workpiece 116. As such,setting the proper position of the stop collar 110 is important.However, being certain what the proper position of the stop collar 110should be has been challenging to date.

To ease the process of properly positioning the stop collar 110 on thedrill bit 102 indicia 108 is placed on drill bit 102 at positions thatcorrespond to common thicknesses of workpieces 116. Indicia 108 is anyvisible indication or marking placed on or into the exterior surface ofdrill bit 102 such as printing, writing, etching, laser-marking,coloring, painting or any other visible marking or combination thereof.In one arrangement, as is shown, in FIGS. 18, 19, 20 and 23 indicia 108includes marking the thickness of workpiece 116 on the shank of thedrill bit 102 such as, ¼, ½, ¾, 1, 1¼, and 1½, and the like. In anotherarrangement, these measurement markings are contained within a band thatwraps around the drill bit 102 in a continuous and uninterrupted mannerand includes markings that indicate the thickness of workpiece 116within the band. This band of marking may or may not be formed of acolor. When the band of indicia 108 is used, the width of the band ofindicia 108 may correspond to the width of the stop collar 110 such thatwhen the stop collar 110 covers the entirety of the band of indicia 108the stop collar 110 is properly aligned. Or, said another way, when theedges of the stop collar 110 are aligned with the edges of the band ofindicia 108 the stop collar 110 is properly aligned. In an alternativearrangement, the band of indicia 108 is slightly wider than the stopcollar 110 such that the band extends beyond the stop collar 110 on eachside of the stop collar 110 when the stop collar 110 is centered on theband. In an alternative arrangement, the band of indicia 108 is slightlynarrower than the stop collar 110 such that the band is completelycovered by the stop collar 110 when the stop collar 110 is centered onthe band.

In one arrangement, indicia 108 is colored. The use of coloring inassociation with indicia 108 helps to draw attention to the indicia 108and makes the indicia 108 easier to see and therefor makes it easier forthe user to align the stop collar 110 to the band. The use of coloringin association with indicia 108 also can be used to ease the process ofselecting the proper position for stop collar 110. In one arrangement,as is shown in FIG. 18, each indicia 108 is associated with a differentcolor. In this arrangement, each indicia 154 on tail section 68 may beassociated with the same color as may be each step 156 on the workpiecethickness gauge 94. In this way, a color-coordinated system 10 ispresented ensuring that when each of the elements, stop collar 110, stopfeature 90 and workpiece thickness gauge 94 correspond to the same colorthe system 10 is properly set. This color may also correspond to a coloron the screws that are to be used. That is, when the workpiece thicknessgauge 94 indicates a blue color for the thickness of workpiece 116, thestop collar 110 is aligned over the blue band of indicia 108 on thedrill bit 102 and the stop feature 90 of tail section 68 is moved to theblue position, and screws are used that are marked with a blue marking.

In one arrangement, to facilitate proper setting of the stop collar 110,stop collar includes an alignment feature 112. Alignment feature 112 isformed of any suitable size, shape and design and is configured to allowthe user to easily understand and ensure that the stop collar 110 ispositioned at the proper position on drill bit 102. In one arrangement,as is shown in FIGS. 18, 19 and 23, alignment feature 112 is a circularopening in stop collar 110. In this arrangement, when the indicia 108 ondrill bit 102 is visible through and centered on the opening ofalignment feature 112 the stop collar 110 is properly set. In thearrangement shown, this opening of alignment feature 112 is generallycircular in shape and is centered in the stop collar 110, and to provideadditional accuracy a circular feature is positioned around the indicia108 (and within the band, when the band is present) on drill bit 102 ofcorresponding size such that when the edges of the circular opening ofalignment feature 112 are aligned with the edges of the circular featuresurrounding the indicia 108 the stop collar 110 is precisely set. Whilea circular shape is shown for use in stop collar 110 as well as for thefeature around indicia 108, any other size, shape and design is herebycontemplated for use such as square, rectangular, oval, triangular,octagonal or any other shape or feature.

In another arrangement, as is shown in FIG. 20, alignment feature 112 isa semi-circular cutout in one side of stop collar 110. In thisarrangement, when the semi-circular alignment feature 112 of stop collar110 cradles the circular feature surrounding indicia 108 the stop collar110 is properly positioned. In one arrangement, this semicircularcut-out of alignment feature 112 is positioned approximately in themiddle of stop collar 110 such that the stop collar 110 can be placed ondrill bit 102 in either orientation and the positioning is not affected.Alternatively, the cut-out of alignment feature is positioned toward oneside of the stop collar 110.

Once the stop collar 110 is properly positioned, the fastener 114extending through the stop collar 110 is tightened using Allen wrench100 and the stop collar 110 is fixed in place and the drill bit 102 isready for use. In one arrangement, grooves are positioned at theposition wherein fastener 114 engaged drill bit 102 when stop collar 110is properly aligned. These grooves then receive fastener therein andhelps to properly align the stop collar 110 at the precise positioningwhen the fastener 114 is tightened and is received within the groove ata particular indicia 108.

In Operation: With reference to FIGS. 1-14, the mini pocket hole jigsystem 10 is formed of a plurality of jig segments 24 connected togetherin side-to-side alignment, either directly to one another or bypositioning one or more spacers 48 between adjacent jig segments 24, byaligning the foot 124 of one jig segment 24 with the receiver 46 of anadjacent jig segment 24 or spacer 48. Once the foot 124 is aligned withthe receiver 46 the foot 124 is inserted within the receiver 46 the twocomponents are rotated ninety degrees (or any other amount or more orless depending on the configuration) with respect to one another therebylocking the foot 124 of one components in the receiver 46 of theadjacent component. The mini pocket hole jig system 10 is assembled byconnecting any number of jig segments 24 and/or spacers 48 inside-to-side alignment for the desired application. Spacers 48 ofvarious thickness are selected based on the desired side-by-side spacingof jig segments 24 and the resulting pocket holes.

When the resulting mini pocket hole jig system 10 of the desired numberof jig segments 24 and/or spacers 48 is formed and the system 10 is tobe used on an inside corner, tail sections 68 are not attached. Incontrast, when the resulting mini pocket hole jig system 10 of thedesired number of jig segments 24 and/or spacers 48 is formed and thesystem 10 is to be used on the side or end of a workpiece 116, tailsections 68 are attached.

Tail sections 68 are attached by sliding the rearward end of the tailsection 68 over the forward end of the jig segments 24 until theconnector 138 is fully received within the opening 142 in the rearwardend 78 of tail section 68. When tail sections 68 are fully attached tojig segments 24, the flange of the tail sections 68 are received withinthe groove 140 of the connector 138 and the protrusions 146 in the lowerend of flanges 144 grip onto the connector 138 thereby holding the tailsection 68 onto connector 138.

When fully assembled the top surfaces of jig segments 24, spacers 48 andtail sections 68 are in planar alignment with one another. When fullyassembled the clamping surfaces of jig segments 24, spacers 48 and tailsections 68 are in planar alignment with one another.

Next, the user measures the thickness of workpiece 116 by usingworkpiece thickness gauge 94. Based on the reading from the workpiecethickness gauge 94, the user adjusts the stop feature 90 of tail section68 to the corresponding thickness. This is accomplished by pressing upon the forward end of stop feature 90 adjacent forward flange 152 untilthe forward arm 148 comes out of the stop 88 that it is held within. Indoing so, the user must overcome the spring bias of the stop feature 90.Next, the user laterally slides the stop feature 90 within slot 86 untilthe stop feature 90 is visible through the opening 90 in the top side 80of the tail section 68 that corresponds with the workpiece thicknessreading from workpiece thickness gauge 94. Once the stop feature 90 isin the desired position, the user releases the stop feature 90 andforward arm 148 falls into the associated stop 88 under the spring biasof the stop feature 90.

Next, the user sets the stop collar 110 on drill bit 102 by aligning thealignment feature 112 of the stop collar 110 with the indicia 108 ondrill bit 102 that corresponds with the workpiece thickness reading fromworkpiece thickness gauge 94. Next, the user tightens the fastener 114using Allen wrench 100.

Next, the user places the clamping surface of the jig segments 24,spacers 48 and tail sections 68 on the upper surface of the workpiece116 and the jig system 10 is slid forward along the workpiece 116 untilthe edge of the workpiece 116 is engaged in a flush and flat manner tothe rearward surface of rearward flange 150 of stop feature 90. Once inthis position, one or more clamps 120 are used to clamp the jig system10 to the workpiece 116. More specifically, the pad 118 of one or moreclamps 120 is placed on the top surface of the jig segments 24, spacers48 and tail sections 68 and then the clamp 120 is tightened. By havingthe top and bottom surfaces of jig segments 24, spacers 48 and tailsections 68 in planar alignment to one another this facilitates evenclamping and pressure across the jig system 10. As the jig system 10 isclamped to the workpiece 116 the layer of grip material is forced uponthe surface of the workpiece 116. Due to the high coefficient offriction of the grip material, upon clamping, the jig system 10 tends tostay in place on the workpiece 116 because the grip material does noteasily slide upon the surface of the workpiece 116.

Once clamped in place, pocket holes are drilled in the workpiece 116 byinserting the drill bit 102 into the drill guides 40 until the stopcollar 110 engages the rearward end of drill guide 40 which protrudesslightly rearward from the rearward end 34 of jig segment 24. Duringdrilling, wood chips and debris formed during drilling pass through thebore formed by drill guide 40 and exit the drilling area through theopening 42 in the top surface of the jig segments 24 that connects tothe hollow bore of the drill guide 40, thereby facilitating a cleanerand nicer drilled hole. Once all pocket holes are drilled, the clamp 120is released and the pocket hole jig 10 is removed.

This process is repeated for all workpieces 116 and the pocket hole jigsystem 10 is assembled and disassembled, configured and reconfigured,based on the particular uses.

In one arrangement, the system is sold as a kit having a plurality ofjig segments 24, a plurality of spacers 48, of the same size or ofvarious sizes, a plurality of tail sections 68, at least one steppeddrill bit 102, at least one stop collar 110, at least one workpiecethickness gauge 94 and an Allen wrench 100 that may or may not be formedas part of the workpiece thickness gauge 94 so that the system may beconfigured in a countless number of configurations.

Alternative Arrangement—Lock Feature and Receiver:

With reference to FIGS. 28-35 an alternative arrangement of a lockfeature 44 and receiver 46 is presented. In this arrangement, receiver46 includes a recess 168 that is sized and shaped to receive aprotrusion 170 positioned on post 122 of lock feature 44. When viewedfrom the side, a recess 168 is positioned approximately in the middle ofthe upper side and lower side of receiver 46. In the arrangement shown,as one example, when viewed from the side, these recesses 168 aresemi-circular in shape or curved in shape. These recesses 168 are sizedand shaped to receive similarly shaped protrusions 170 on post 122 oflock feature 44. However, protrusions 170 of lock feature 44 arepositioned on the forward and/or rearward side of post 122, so as tofacilitate insertion of post 122 into receiver 46 when the adjacent jigsegments 24 and/or spacers 48 are connected in a perpendicular manner.In one arrangement, as is shown, when viewed from the side, protrusions170 on posts 122 extend slightly past the forward and back sides of foot124. Also, as is shown, the outward edge of protrusion 170 on posts 122is angled or chamfered toward foot 124. This angled feature helps toguide the foot 124 within the hollow interior of jig segment 24 and/orspacer 48 as the two components are rotated with respect to one anotherthereby ensuring full insertion and locking of the adjacent jig segments24 and/or spacers 48 that are connected together.

By recesses 168 of receiver 46 receiving the protrusions 170 of post 122of lock feature 44 within close and tight tolerances, this engagementprovides alignment to the adjacent jig segments 24 and/or spacers 48that are being connected together. Said another way, without theengagement of recesses 168 and protrusions 170, the adjacent jigsegments 24 and/or spacers 48 that are being connected together can moverelative to one another as the post 122 can move around within theoblong-shaped receiver 46. By including recesses 168 in receivers 46 andprotrusions 170 in posts 122 this ensures the lock feature 44 iscentered within the receiver 46. This centering provides alignment andguidance and ensures that the adjacent jig segments 24 and/or spacers 48that are being connected together are easily locked together in a quick,easy and simple manner.

Also shown in this arrangement, as one example, bars 130 and recess 128are positioned within a groove 172 that extends the vertical length ofthe sides of jig segments 24 and/or spacers 48. This groove 172 isconfigured to receive and guide protrusion 126 in the side of jigsegment 24 and/or spacers 48 toward and into the recess 128 between bars130. This guidance provided by groove 172 to protrusion 126 ensuresproper and easier locking of the adjacent jig segments 24 and/or spacers48.

Insert Ramps:

In one arrangement, as is shown with reference to FIGS. 36-38, the lowerinterior edges of the sides 72, 74 of tail section 68 include insertramps 174. Insert ramps 174 are formed of any suitable size, shape anddesign and are configured to ease the insertion of stop feature 90 intothe hollow interior 84 of tails section 68. More specifically, insertramps 174 connect to the bottom edge of the interior side of sidewalls72, 74 and angle inward as they extend upward. In the arrangement shown,as one example, two insert ramps 174 are presented, one to receive eachof the arms 148 of stop feature 90. To insert stop feature 90 into thehollow interior 84 of tail section 68, arms 148 of stop feature 90 arealigned with insert ramps 174 of tail section 68. Once aligned, the stopfeature 90 is forced upward into hollow interior 84. As stop feature 90is forced upward, the sides 72, 74 flex outward as the insert ramps 174guide the arms 148 upward. This continues until arms 148 pass the upperend of insert ramps 174 and enter slot 86 of tail section 68 at whichpoint stop feature 90 is fully inserted within tail section 68 and thestop feature 90 is free to move forward and back within hollow interior84 in a sliding fashion with arms 148 guided by and slot 86.

Alternative Arrangement—Stop Feature:

An alternative arrangement of stop feature 90 is presented withreference to FIGS. 39-42. In this arrangement, tail section 68 includesa groove 176 positioned in each exterior side 172, 174 of tail section68 that runs laterally a distance along the length of tail sections 68.In the arrangement shown, these grooves 176 are positioned within a step178, which narrows the width of the lower section of tail section 68. Inthis arrangement, grooves 176 extend from adjacent the forward end oftail section 68 until they terminate at step 178. In the arrangementshown, as one example, when viewed from the forward end of tail section68, grooves 176 are generally square or rectangular in shape. Also, inthe arrangement shown, as one example, the lower side of grooves 176include stops 88 which are sized and shaped to receive arms 148 in stopfeature 90 and are configured to set the position of stop feature 90 atvarious predetermined workpiece thicknesses.

In this arrangement, as one example, stop feature 90 includes a pair offlanges 180 that extend upward in approximate parallel spaced relation.Flanges 180 are spaced from one another and are sized and shaped toreceive the lower end of tail section 68 within step 178. The upper endof flanges 180 includes guides 182 that are sized and shaped to fitwithin and slide along grooves 176. That is, in this arrangement, stopfeature 90 is installed onto tail section 68 by aligning the inwardlyextending guides 182 at the upper end of flanges 180 with the grooves176 in the opposing sides of tail section 68. Once aligned in thismanner, stop feature 90 is forced forward such that the guides 182 slidewithin grooves 176 and stop feature 90 fits around the lower end of tailsection 68.

In this arrangement, the forward flange 152 is spring biased and isconnected to the rearward flange 150 by hinge member 184 which allowsforward flange 152 to flex up and down. As the forward end of forwardflange 152 is pushed upward, forward flange 152 bends, flexes and/orarticulates upward upon hinge member 184. Forward flange 152 includes apair of flanges 186 that extend upward in approximate parallel spacedrelation. Flanges 186 are spaced from one another and are sized andshaped to receive the lower end of tail section 68 within step 178. Theupper end of flanges 186 includes arms 148 that are sized and shaped tofit within and slide along grooves 176 until they drop into stops 88 inthe lower side of grooves 176 under the spring bias of hinge member 184.When the rearward flange 150 is installed on the tail section 68, andstop member 90 is slid rearward as the guides 182 slide within grooves176, the forward flange 152 is pushed upward so as to align the arms 148with grooves 176. Once forward flange 186 is pushed upward, causingforward flange 152 to flex and rotate upon hinge member 184, arms 148are received within grooves 176. Once in this position, stop member 90may be slid forward upon tail section 68 as the arms 148 and guides 182slide within grooves 176. This sliding continues until stop member 90 ispushed rearward far enough until the arms 148 reach the first set ofstops 88. Once the stop member 90 is pushed or slid far enough until thearms 148 reach stops 88, due to the spring bias of hinge member 184 thearms 148 fall or are pushed into grooves 88 under the spring bias ofhinge member 184. In this position, stop members 90 are locked in placeat a predetermined thickness that corresponds to a common workpiecethickness. To move the stop member 90 upon the tail section 68, theforward flange 150 is pushed upward, causing forward flange to rotate orflex on hinge member 184, until the arms 148 come out of grooves 88.Once arms 148 come out of grooves 88, stop member 90 may be slid alongtail section 68 until the arms 148 again fall into another set ofgrooves 88.

This arrangement presents a relatively rigid tail section 68 and arelatively strong and durable stop feature 90. In this arrangement,because there are no slots or grooves 86 that extend through thesidewalls of tail section 68, the tail section 68 can withstandtremendous clamping pressure without breaking or collapsing.

Connected Jig Segments by a Combination of Rotating and Sliding:

With reference to FIGS. 43-63 and 109-128 an alternative arrangement ofa mini pocket hole jig system 10 is presented. In this arrangement,adjacent jig segments 24 connect to one another with a combination ofrotational movement as well as sliding movement. In doing so, adjacentjig segments 24 are essentially locked in place and are held togetherwith superb strength rigidity and are practically impossible tounintentionally disconnect from one another. In addition adjacent jigsegments 24 are held together with little to no relative movement to oneanother due to the rotating and sliding locking connection. Notably,FIGS. 43-63 do not show a spacer 48. However, a spacer 48 is herebycontemplated and operates in the same manner as is described herein withrespect to jig segments 24. That is, spacers 48 include the samefeatures as is described herein with respect to jig segments 24 andoperate in the same manner as jig segments 24. As such, discussionregarding features of jig segments 24 applies equally to spacers 48.Also, FIGS. 43-63 do not show tail sections 68, however all teachingsregarding tail sections 68 herein apply equally to the embodiments shownin FIGS. 43-63. Tail sections are shown in FIGS. and 109-128.

For the purposes of reducing redundancies and being concise, jigsegments 24, and spacers 48, of the embodiment of FIGS. 43-63 and109-128 include and incorporate all of the teachings described hereinwith respect to other embodiments of the system 10, unless specificallydescribed otherwise. That is, the embodiment of FIGS. 43-63 i and109-128 includes the previously described features and functionality ofother embodiments unless specifically described otherwise.

In the arrangement shown, as one example, jig segments 24 include afirst lock feature 44 positioned in a side 28, 30 of jig segment 24positioned at one end 32, 34 of the jig segment 24, and a second lockfeature 44 positioned at the other end 32, 34 of the jig segment 24,with both the first lock feature 44 and second lock feature 44protruding out of the same side 28, 30 of the jig segment 24. In thearrangement shown, as one example, jig segments 24 include a firstreceiver 46 that is configured to receive first lock feature 44 and asecond receiver 46 that is configured to receive second lock feature 44.

Lock Features:

In the arrangement shown, as one example, in FIGS. 43-63 and 109-128lock features 44 are positioned in the left side 28 of jig segment 24and receivers 46 are positioned in the right side 30 of jig segment 24,however the opposite is hereby contemplated as well, as well as anyother placement. In the arrangement shown, as one example, in FIGS.43-63 and 109-128 first lock feature 44 is positioned adjacent theforward end 32 of jig segment 24 and second lock feature 44 ispositioned adjacent the rearward end 34 of jig segment 24, however theopposite is hereby contemplated as well, as well as any other placement.The farther the two lock features 44 are spaced from one another thegreater the strength and stability of the connection. In the arrangementshown, as one example, in FIGS. 43-63 first receiver 46 is positionedadjacent the forward end 32 of jig segment 24 and second receiver 46 ispositioned adjacent the rearward end 34 of jig segment 24, however theopposite is hereby contemplated as well, as well as any other placement.

In this arrangement, first lock feature 44 and second lock feature 44are similar to one another in that they both include a post 122 thatconnects to the side of jig segment 24 and extends outward therefrom adistance before connecting to a foot 124 connected to the outward end ofpost 122. Post 122 and foot 124 are dimensionally different. That is,when viewed from the side, foot 124 of both lock features 44 is largerthan post 122. Or, said another way, foot 124 extends past the exteriorsurfaces of post 122 at least in some places. This dimensionaldifference between posts 122 and feet 124 facilitates locking ofadjacent jig segments 24 and prevents lateral separation of adjacent jigsegments 24 once attached to one another.

In the arrangement shown, as one example, first lock feature 44 ispositioned adjacent the upper side of the forward end 32 of the sidewallof jig segment 24, however any other placement is hereby contemplated.In the arrangement shown, as one example, second lock feature 44 ispositioned adjacent the lower side of the rearward end 34 of thesidewall of jig segment 24, however any other placement is herebycontemplated.

First Lock Feature:

In the arrangement shown, as one example, when viewed from the side, thepost 122 of first lock feature 44 is generally rectangular in shape andextends outward of the surface of sidewall of jig segment 24 in agenerally perpendicular manner. The generally flat upper and lowersurfaces of this rectangular shaped post 122 are positioned at an angleto the generally flat planes formed by the top side 36 and clampingsurface 38 of jig segment 24. That is, the generally flat and planarupper and lower surfaces of post 122 of first lock feature 44 angledownward toward clamping surface 38 as they extend from rearward end 34to forward end 32.

In the arrangement shown, as one example, foot 124 of first lock feature44 is generally square or diamond shaped when viewed from a side, andgenerally flat and rectangular when viewed from the forward end 32 orrearward end 34 and includes generally flat and planar interior andexterior surfaces. In the arrangement shown, as one example, theinterior and exterior surfaces of foot 124 of first lock feature 44extend in approximate parallel spaced alignment to the surface of side28 of jig segment 24 and extends in approximate perpendicular alignmentto the upper and lower surfaces of post 122 and the length of extensionof post 122. In the arrangement shown, as one example, the upper andlower ends of foot 124 extend above and below the upper and lowersurfaces of post 122, respectively. However, any other shape orconfiguration is hereby contemplated for use.

Second Lock Feature:

In the arrangement shown, as one example, the post 122 of second lockfeature 44 is generally cylindrical in shape and extends outward of thesurface of sidewall of jig segment 24 in a generally perpendicularmanner. In the arrangement shown, as one example, foot 124 of secondlock feature 44 is generally square when viewed from a side, andgenerally flat and rectangular when viewed from the forward end 32 orrearward end 34 and includes generally flat and planar interior andexterior surfaces. In the arrangement shown, as one example, theinterior and exterior surfaces of foot 124 of second lock feature 44extend in approximate parallel spaced alignment to the surface of side28 of jig segment 24 and extends in approximate perpendicular alignmentto the length of extension of post 122. However, any other shape orconfiguration is hereby contemplated for use.

In the arrangement shown, as one example, the exterior edges of foot 124of first lock feature 44 and second lock feature 44 are curved, sloped,chamfered or otherwise angled so as to facilitate easier insertion intoreceivers 46 and connection to adjacent jig segments 24 or spacers 68.

First Receiver:

In the arrangement shown, as one example, on the opposite side of jigsegment 24 from first lock feature 44 and second lock feature 44, isfirst receiver 46. First receiver 46 is formed of any suitable size,shape and design and is configured to receive and hold first lockfeature 44 while also allowing first lock feature 44 to rotate withinfirst receiver 46 as well as slide into a fully locked position withinfirst receiver 46. In the arrangement shown, as one example, firstreceiver 46 includes an opening 200 that has a corresponding size andshape so as to receive the foot 124 of first lock feature 44 thereinwith close and tight tolerances. With that said, the shape of opening200 is configured to receive foot 124 in a particular orientation, as isdescribed further herein. In one arrangement, the shape of opening 200only allows the insertion of foot 124 therein in a single angularalignment while preventing the insertion of foot 124 in a differentangular orientation or an opposite angular orientation. Opening 200 alsoincludes recesses or other features that accommodate the elongatedrectangular shape of post 122 of first lock feature 122 as the jigsegments 24 are rotated with respect to one another to facilitateconnection and assembly of adjacent jig segments 24. In the arrangementshown, as one example, the edges of opening 200 are curved, chamfered orangled inward slightly so as to facilitate easy insertion of foot 124 offirst lock feature 44 therein.

In the arrangement shown, as one example, first receiver 46 includes arelief 202. Relief 202 is formed of any suitable size, shape and designand is configured to receive post 122 of first lock feature 44 as thetwo adjacent jig segments are slid with respect to one another. In thearrangement shown, as one example, relief 202 has a corresponding sizeand shape so as to receive the post 122 of first lock feature 44 thereinwith close and tight tolerances as the two jig segments 24 are slid withrespect to one another. That is, in the arrangement shown, as oneexample, wherein when the post 122 of first lock feature 44 is generallyrectangular in shape, relief 202 is similarly rectangular shaped andorientated to receive the post 122 when it slides forward into relief202. With that said, the angle and position of the shape of relief 202is configured to only align and receive post 122 after the foot 124 hasbeen fully inserted within opening 200 followed by rotation of the jigsegments 24 relative to one another. Once the jig segments 24 have beenfully rotated with respect to one another, such that their clampingsurfaces 38 are in generally flat and flush planar alignment, at thattime, and only at that time does relieve 202 align with post 122. Oncealigned, jig segments 24 may be slid with respect to one another atwhich point in time the rectangular shaped post 122 of first lockfeature is received within the rectangular shaped relief 202 connectedto opening 200.

In the arrangement shown, as one example, relief 202 is connected to therearward side of opening 200. Also, in the arrangement shown, as oneexample, the upper and lower surfaces of relief 202 extend upward at anangle from clamping surface 38 to top side 36 as relief extends rearwardfrom opening 200 toward rearward end 34. Any other position or shape ishereby contemplated for use.

In the arrangement shown, as one example, when first lock feature 44 ispositioned within first receiver 46 and is fully rotated as well as slidin place, the upper surface of post 122 is in approximate flat and flushengagement with the upper surface of relief 202; the lower surface ofpost 122 is in approximate flat and flush engagement with the lowersurface of relief 202; the rearward end of post 122 is in approximateflat and flush engagement with the rearward end of relief 202; and theinward facing surface of foot 124 that extends past post 122 is in flatand flush engagement with the inward surface of the area adjacent torelief 202. In this position, first lock feature 44 is fully locked inplace within first receiver 46 and is prevented from laterally pullingout of first receiver 46.

Once fully assembled, to remove first lock feature 44 from firstreceiver 46, first lock feature 44 is slid away from the end of relief202 and toward opening 200. Once post 122 of first lock feature 44enters opening 200 the two jig segments 24 are rotated with respect toone another until the features of foot 124 of first lock feature 44aligns with the features of opening 200 at which point the two jigsegments 24 may be laterally moved away from one another as the foot 124of one jig segment 24 moves out of the opening 200 of the first receiver46 of the other jig segment 46.

Second Receiver:

In the arrangement shown, as one example, a second receiver 46 ispositioned on the same side of jig segment 24 as first receiver 46,however the opposite arrangement is hereby contemplated for use. Butunlike first receiver 46, which is positioned adjacent the forward end32 of jig segment 24, second receiver 46 is positioned adjacent therearward end 34 of jig segment 24, however the opposite arrangement ishereby contemplated for use. Second receiver 46 is formed of anysuitable size, shape and design and is configured to receive and holdsecond lock feature 44 while also allowing second lock feature 44 torotate into second receiver 46 as well as slide into a fully lockedposition within second receiver 46. In the arrangement shown, as oneexample, second receiver 46 includes a slot 204 that connects to a neck206 and includes a collar 208 positioned between the slot 204 and neck206. However any other shape is hereby contemplated for use.

In the arrangement shown, as one example, second receiver 46 includes aslot 204 that is sized and shaped to receive post 122 of second lockfeature 44 therein with close and tight tolerances as the two jigsegments 24 are rotated with respect to one another. Notably, the size,shape and orientation of the opening 200 of the first receiver 46 isconfigured to only allow insertion of foot 124 of lock feature 44 intoopening 200 when the second lock feature 44 is positioned below secondreceiver 46 such that when the two jig segments are rotated togethersecond lock feature 44 rotates toward and into second receiver 46through slot 204. In the arrangement shown, as one example, slot 204connects with the clamping surface 38. Or, said another way, slot 204opens on its bottom side at clamping surface 38. In this way, as the twojig segments 24 are rotated with respect to one another the post 122 ofsecond lock 44 feature slides upward within slot 204 while the largerfoot 124 is captured in the space behind slot 204 within the body of jigsegment 24. In the arrangement shown, as one example the lower end ofslot 204 is curved, chamfered or otherwise angled to help guide theinsertion of post 122 into slot 204 which eases assembly.

In the arrangement shown, as one example, slot 204 extends upward adistance from clamping surface 38 and the upper end of slot 204 connectsto a neck 206. Like, slot 204, neck 206 is sized and shaped to receivepost 122 of second lock feature 44 therein. In the arrangement shown, asone example, neck 206 extends rearward from slot 204 a distance and atan angle. In the arrangement shown, as one example, neck 206 extendsrearward from slot 204 a distance and at an angle that is similar to ifnot identical to the distance and angle that relief 202 extends fromfirst receiver 46.

In the arrangement shown, as one example, a collar 208 is positionedbetween slot 204 and neck 206. Collar 208 forms a narrow spot betweenslot 204 and neck 206. In this way, as the post 122 of second lockfeature 44 moves from slot 204 to neck 206 the narrower collar 208imparts friction on post 122 which requires force to overcome. Onceenough force is applied and post 122 moves past collar 208, post 122 isfrictionally held within neck 206 with tight and close frictionaltolerances. To move post 122 from slot 204 to neck 206, jig segments 24are slid with respect to one another. Once post 122 of second lockfeature 44 is held within neck 206 due to the narrower collar 208 toremove post 122 from neck 206 enough force is applied to cause post 122to overcome the frictional engagement of collar 208 on post 122. Oncethe post 122 is slid past collar 208 by laterally sliding adjacent jigsegments 24 with respect to one another, the post 122 enters slot 204and the two jig segments 24 may be rotated with respect to one anotherthereby allowing the post 122 of second lock feature 44 to exit thelower end of slot 204.

In this way, the combination of the features of first lock feature 44and second lock feature 44 and first receiver 46 and second receiver 46work in concert with one another to facilitate a secure connectionbetween two adjacent jig segments 24 and/or spacers 48 by bothrotational movement as well as by sliding movement.

Additional Lock Features and Receivers:

In the arrangement shown, as one example, only a single first lockfeature 44 and a single first receiver 46 may be used as the jigsegments 24 rotate upon this connection point between first lock feature44 and first receiver 46. In the arrangement shown, only a single secondlock feature 44 and a single second receiver 46 is shown for use.However, it is hereby contemplated that any number of second lockfeatures 44 and second receivers 46 may be included in jig segment 24.These additional second lock features 44 and second receivers 46 may beplaced at any position along any portion of the sides 28, 30 of jigsegment 24, such as two, three, four, five or more second lock features44 and second receivers 46. The addition of additional second lockfeatures 44 and second receivers 46 provides additional strength andrigidity and strength of hold between opposing jig segments 24. Also,while second receivers 46 and second lock features 44 are shown adjacentthe lower end of sides 28, 30 at the intersection of sides 28, 30 andclamping surface 38, it is hereby contemplated that second receivers 46and second lock features 44 may be placed at the intersection of the topside 36 and sides 28, 30 as well.

Screw Receivers:

In the arrangement shown, as one example, the sides 28, 30 of main body26 of jig segments 24 include screw receivers 210. Screw receivers 210are formed of any suitable size, shape and design and are configured tofacilitate the attachment of jig segment 24 to a workpiece 116. That is,in some situations, such as repairing a shelf or a table leg or acabinet or another part, it is necessary to attach jig segment 24 in away where a clamp 120 cannot be used. In this situation, jig segment 24is placed against the workpiece 116 at the position where the pockethole is to be drilled and a screw or nail or other attachment member ispassed through screw receiver(s) 210 thereby holding the jig segment 24in place. Once the jig segment 24 is held in place, a pocket hole may bedrilled in the workpiece 24. Once the pocket hole is drilled, the nail,screw or other attachment member is removed thereby allowing for removalof the jig segment from the workpiece 116.

In the arrangement shown, as one example, a screw receiver 210 ispositioned in each side 28, 30 of jig segment 24. In the arrangementshown, as one example, screw receiver 210, when viewed from above orbelow, is formed of approximately a half circle cut-out in the side 28,30 of jig segment 24 that extends in a generally constant manner fromtop side 36 through clamping surface 38. In the arrangement shown, asone example, screw receivers 210 are positioned at about the middle ofjig segment 24, with one screw receiver 210 positioned in each side 28,30 such that the opposing jig segments 24 are aligned with one another,one on each side 28, 30.

When only a single jig segment 24 is used, a nail, screw or otherattachment member is placed in each screw receiver 210. In this way, jigsegment 24 is sandwiched between opposing nails or screws held inopposing sides of the jig segments 24. In this way, two screws are used,one in each screw receiver 210, to hold a single jig segment 24 toworkpiece 116.

When two or more jig segments 24 (or a jig segment 24 and a spacer 48for that matter), are connected together in side-by-side alignedconnection, the screw receiver 210 of one jig segment 24 aligns with thescrew receiver 210 of the other jig segment 24. In this way, when twojig segments 24 are connected together the adjacent screw receivers 210form a cylindrical opening between the combined jig segments 24 that isconfigured to receive a screw or nail or other fastening member therein.In this arrangement, when two jig segments 24 are used a single nail,screw or other attachment member may be placed in the combined screwreceivers 210 between the two jig segments 24. In this way, the singlescrew, nail or other attachment mechanism is sandwiched between adjacentjig segments 24. In this way, a single screw or nail or other attachmentmechanism may be used to hold a two or more jig segments 24 to workpiece116. In this arrangement, additional screws or nails may also beinserted in the exterior-positioned screw receivers 210 as well as thecentrally positioned screw receiver(s) 210.

While only a single screw receiver 210 is shown placed in each side 28,30 of jig segments 24, any number of screw receivers 210 are herebycontemplated for use, such as two, three, four, five or more. Inaddition, while a semi-circular shaped screw receiver 210 is shown, anyother shape is hereby contemplated for use such as square, rectangular,triangular, oval, or the like. In addition, while screw receivers 210are shown as recesses in the sides 28, 30 of jig segments 24, it ishereby contemplated for use that screw receivers 210 may be formed ofopenings that extend through the main body 26 of jig segments 24. Anyother configuration for jig segments 210 is hereby contemplated for use.

Ramps:

In the arrangement shown, as one example, sidewalls 28, 30 of jigsegments 24 include one or more ramps 212. Ramps 212 are formed of anysuitable size, shape and design and are configured to provide frictionalengagement between opposing jig segments 24 when opposing jig segments24 are in a fully assembled state. In addition, ramps 212 are configuredto force adjacent jig segments 24 away from one another when opposingjig segments 24 are in a fully assembled state thereby increasing thestrength of hold and tension between the connecting surfaces of feet 124of one jig segment 24 with the receiver 46 of the other jig segment 24.The presence of ramps 212 creates a more rigid overall tool whenmultiple jig segments 24 and/or spacers 48 are connected to one another.

In the arrangement shown, as one example, a plurality of ramps arepositioned in the sides 28, 30 of jig segments 24 spaced between theforward end 32 and the rearward end 34. In the arrangement shown, threeramps 212 are positioned in spaced relation along sides 28, 30 of jigsegments 24, however any other number of ramps 212 are herebycontemplated for use including zero, one, two, three, four, five, six ormore. In the arrangement shown, as one example, when viewed from aboveor below, ramps 212 are generally smooth rounded or curved protrusionsthat bulge slightly outward from the generally planar sides 28, 30 ofjig segments 24. In the arrangement shown, ramps 212 extend in agenerally consistent fashion outward from sides 28, 30 from the top edgeof the sides 28, 30 to the bottom edge of the sides 28, 30, however insome arrangements the sides 28, 30 angle slightly outward as they extenddownward from the top side 36 to the clamping surface 38. The use oframps 212 is particularly useful in facilitating a secure connectionbetween jig segments 24 and spacers 48 in the arrangement where adjacentjig segments 24 are connected together in a sliding fashion.

FIG. 96, is a close-up top view of two adjacent jig segments 24 thathave been connected together by inserting the first lock feature 44 ofone jig segment 24 into the first receiver 46 of the other jig segment24and the two jig segments 24 have been rotated such that their clampingsurfaces 38 are in planar alignment. As shown in FIG. 96, in thisposition, the ramps 212 of each jig segment 24 are off-set from oneanother. That is, said another way, the peak of the curved surface ofthe ramps 212 of one jig segment 24 engage the side 28, 30 of the otherjig segment 24. In this view, the ends 32, 34 of adjacent jig segments24 are laterally offset.

FIG. 97 is the same close-up top view of two adjacent jig segments 24shown in FIG. 96, however in FIG. 97 the two jig segments 24 have beenslid laterally with respect to one another such that the ends 32, 34 ofthe adjacent jig segments 24 are laterally aligned with one another. Inthis position, the ramps 212 of each jig segment 24 are aligned with oneanother. That is, said another way, the peak of the curved surface ofthe ramps 212 of one jig segment 24 engage the peak of the curvedsurface of the ramps 212 of the other jig segment 24. This engagement ofadjacent ramps 212 has the effect of pushing adjacent jig segments 24away from one another which has the tendency to strengthen theconnection between the lock features 44 of one jig segment 24 and thereceivers of the other jig segment 24. Engagement of the peaks of ramps212 of adjacent jig segments 24 has a tendency to form a more-rigidcombined pocket hole jig system 10. In the arrangement shown, as oneexample, as the adjacent jig segments 24 are slid with respect to oneanother to achieve a fully assembled state, the curved surface of theramps 212 of one jig segment 24 smoothly slide over the curved surfaceof the ramps 212 of the other jig segment 24 until the ramps 212 ofopposing jig segments 24 are in peak-to-peak engagement. In onearrangement, there is a flat section at the peak of ramps 212 whichfacilitates a natural resting area for adjacent ramps 212 to engage oneanother.

Method of Assembly:

To assemble the mini pocket hole jig system 10 of FIGS. 43-63, thefollowing steps are performed:

Step 1—Insert First Lock Feature of one Jig Segment into First Receiverof the other Jig Segment: With reference to FIGS. 43-49, the first lockfeature 44 in the forward end 32 of one jig segment 24 is inserted intothe first receiver 46 in the forward end 32 of the other jig segment 24.To accomplish this, the two jig segments 24 are held at an angle to oneanother such that the shape of the foot 124 of the first lock feature 44of one jig segment 24 aligns with the shape of the opening 200 of thefirst receiver 46 of the other jig segment 24. In one arrangement, thisalignment between the foot 124 of the first lock feature 44 of one jigsegment 24 aligns with the shape of the opening 200 of the firstreceiver 46 of the other jig segment 24 can only be accomplished in oneparticular orientation, due to the shape of the foot 124 and opening200, thereby preventing improper assembly. Once the foot 124 of thefirst lock feature 44 of one jig segment 24 aligns with the shape of theopening 200 of the first receiver 46 of the other jig segment 24 thefoot 124 of one jig segment 24 is inserted into the opening 200 of theother jig segment 24.

Step 2—Rotate The Jig Segments Until The Clamping Surfaces Align: Withreference to FIGS. 50-55, with the first lock feature 44 in the forwardend 32 of one jig segment 24 inserted into the first receiver 46 in theforward end 32 of the other jig segment 24, the two jig segments 24 arerotated with respect to one another until the clamping surfaces 38 ofthe adjacent jig segments 24 are in planar alignment with one another.This rotation occurs upon the axis of rotation formed by the engagementbetween the first lock feature 44 of one jig segment 24 with the firstreceiver 46 of the other jig segment 24. As the adjacent jig segments 24are rotated with respect to one another, the second lock feature 44 ofone jig segment 24 engages the second receiver 46 of the other jigsegment 24. That is, as the adjacent jig segments 24 are rotated withrespect to one another the foot 124 and post 122 of the second lockfeature 44 of one jig segment 24 pass through the slot 204 of the secondreceiver 46 of the other jig segment 24. In this position, the planarclamping surfaces 38 and top sides of the adjacent jig segments 24 arein planar alignment to one another. However, the ends 32 34 of theadjacent jig segments 24 are offset from one another, as are the ramps212, screw receivers 210.

Step 3—Slide The Jig Segments Until The Ends Align: With reference toFIGS. 56-63, with the first lock feature 44 in the forward end 32 of onejig segment 24 inserted into the first receiver 46 in the forward end 32of the other jig segment 24, and the second lock feature 44 in therearward end 34 of one jig segment 24 inserted into the second receiver46 in the rearward end 34 of the other jig segment 24, and with theplanar clamping surfaces 38 and planar top sides 36 of adjacent jigsegments 24 in alignment , the two jig segments 24 are slid with respectto one another until the ends 32, 34 of adjacent jig segments 24 are inalignment with one another. That is, in this position, the adjacent jigsegments 24 are slid laterally with respect to one another. Or, saidanother way, the adjacent jig segments 24 are slid along an axis thatextends along the length of the main body 26 of jig segments 24 fromforward end 32 to rearward end 34. As the adjacent jig segments 24 areslid with respect to one another several events occur simultaneously.First, the post 122 of the first lock feature 44 of one jig segment 24enters the relief 202 connected to the opening 200 of the other jigsegment 24. In one arrangement, there is a frictional engagement or afriction imparting member that causes engagement between the post 122and relief 202 that helps to hold the post 122 into the relief 202 andhelps to prevent unintentional disengagement. Second, the post 122 ofthe second lock feature 44 of one jig segment 24 enters the neck 206 ofthe second receiver 46 of the other jig segment 24. In one arrangement,there is a frictional engagement or a friction imparting member thatcauses engagement between the post 122 and neck 206 (such as collar 208)that helps to hold the post 122 into the neck 206 and helps to preventunintentional disengagement. Third, the ramps 212 of the adjacent jigsegments 24 slide over one another until they are in peak-to-peakengagement with one another. As the adjacent ramps 212 slide over oneanother they force the adjacent jig segments 212 away from one anotherthereby strengthening the connection between the lock features 44 andreceivers 46 of the adjacent jig segments 24.

To disassemble fully connected jig segments 24, the opposite process isperformed.

In this way a mini pocket hole system 10 is assembled from a pluralityof jig segments 24 and/or spacers 48 by a combination of rotation aswell as sliding. Assembly and disassembly is quick and easy and does notrequire any tools. Once assembled, the component parts are held togetherin a rigid and secure manner that practically eliminates the possibilityof unintentional detachment.

Clamp Pad Attachment Mechanism:

With reference to FIGS. 64-95, a clamp pad attachment mechanism 220 ispresented. Clamp pad attachment mechanism 220 is formed of any suitablesize, shape and design and is configured to facilitate secure attachmentof a clamp 120 to mini pocket hole jig system 10. In the arrangementshown, as one example, clamp pad attachment mechanism 220 includes abase 222, an adjustment member 224 and a connector 226 that work inconcert with one another to connect to and hold the pad 118 of a clamp120 and connect the clamp 120 to the mini pocket hole jig system 10.

In the arrangement shown, as one example, clamp pad attachment mechanism220 includes a base 222. Base 222 is formed of any suitable size, shapeand design and is configured to connect to the pad 118 of a clamp 120 aswell as attach to the main body 26 of a jig segment 24 or a spacer 48 ofa mini pocket hole jig system 10. In the arrangement shown, as oneexample base 222 when viewed from above or below forms a generallysquare or rectangular member with generally flat and straight ends 228that extend in approximate parallel spaced relation to one another, andgenerally flat and straight sides 230 that extend in approximateparallel spaced relation to one another. Base 222 has a generally flatand planar upper surface 232 that extends in approximate parallel spacedrelation to a generally flat and planar lower surface 234.

In the arrangement shown, as one example, base 222 includes an arm 236that is positioned toward one end 228. In this arrangement, arm 236extends upward a distance above the planar upper surface 232 of base222. A plurality of fingers 238 extend forward from the upper end of arm236 a distance over the planar upper surface 232. In this way, a spaceor lip is formed by the forward extension of fingers 238 from the upperend of arm 236. That is, a space is formed between the lower surface offingers 238 an d the upper surface 232 of base 222. This space isconfigured to receive and hold the edge of a pad 118 of a clamp 120therein.

In the arrangement shown, as one example, a rail 240 extends along eachside 230 of base 222 between opposing ends 228. In the arrangementshown, as one example, rails 240 include a plurality of notches or teeth242 therein. In the arrangement shown, as one example, rails 240 andteeth 242 facilitate slidable connection of adjustment member 224 tobase 222.

In the arrangement shown, as one example, base 222 includes a keyhole244 positioned approximately in the center of base 222. Keyhole 244 isformed of any suitable size, shape and design and is configured toreceive and hold connector 226 therein. In the arrangement show, as oneexample, keyhole 244 includes an opening 246 that connects to a slot 248that is narrower than the opening 246 and has a pair of rails 250positioned on each side of the slot 248 and form a step below uppersurface 232 of base 222.

In the arrangement shown, as one example, clamp pad attachment mechanism220 includes an adjustment member 224. Adjustment member 224 is formedof any suitable size, shape and design and is configured to connect tobase 222 and slidably adjust its position so as to facilitate attachmentof clamp pad attachment mechanism 220 to the pad 118 of a clamp 120. Inthe arrangement shown, as one example, adjustment member 224 includes anarm 254 that extends upward and includes a plurality of fingers 256 thatextend forward from the arm 254.

In the arrangement shown, as one example, adjustment member 224 includesa pair of wings 258, one at each side of arm 254. These wings 258 extendforward from arm 254 at each outward side of arm 254 a distance and areconfigured to slidably connect to rails 240 in the sides 230 of base222. The outward ends of wings 258 include a locking mechanism 260 thatincludes a catch 262 that is configured to engage the teeth 242 of rails240 of base 222. In the arrangement shown, as one example, these lockingmechanisms 260 are under a spring bias such that in their natural statewhen adjustment member 224 is connected to base 222, the lockingmechanisms 260 have a tendency to move outward and away from base 222.This spring bias causes catch 262 to engage the teeth 242 on the insidesurface of rail 240 thereby locking the position of adjustment member224 on base 222. Notably, teeth 242 and catches 262 are configured tofacilitate easy installation by being one-way, meaning that theadjustment member 224 may be slid onto the base 222 and the catches 262will automatically move over the teeth 242 as the adjustment member 224moves toward the arm 236 of base 222, however movement in the oppositedirection, away from the arm 236 of base 222 is prevented. To moveadjustment member 224 away from the arm 236 of base 222 pressure isapplied to the outside surfaces of locking mechanisms 260. This causesthe catches 262 to move inward and out of engagement with the teeth 242which allows the adjustment member 224 to be slid away from the arm 236of base 222. This arrangement allows the pad 118 of a clamp 120 to beplaced under the fingers 238 of base 222 an d then the adjustment member224 is slid forward until the fingers 252 overhang the pad 118 of clamp120. In this position, the pad 118 of clamp 120 is captured between thearm 236 and fingers 238 of base 222 and the arm 254 and fingers 256 ofadjustment member 224. Also, in this position, adjustment member 224 isprevented from moving backwards as the spring bias of locking mechanisms260 holds catches 262 into engagement with teeth 242. To remove the pad118 of clamp from clamp pad attachment mechanism 220, the lockmechanisms 260 of adjust member 224 are forced inward, thereby releasingcatches 262 from teeth 242 and the adjustment member 224 is slid awayfrom arm 236 on rails 240 thereby releasing the pad 118 of clamp 120. Inthis way, base 222 and adjustment member 224 are configured to quicklyand easily and securely attach to the pad 118 of a clamp 120, while alsoallowing for quick and easy removal.

In the arrangement shown, as one example, clamp pad attachment mechanism220 includes a connector 226. Connector 226 is formed of any suitablesize, shape and design and is configured to connect to the clamp padattachment mechanism 220 to a jig segment 24 or spacer 48. In thearrangement shown, as one example, connector 226 has an upper end 264, alower end 266 and a neck 268. In the arrangement shown, as one example,upper end 264 is generally cylindrical in shape and is configured to fitthrough the opening 246 in the keyhole 244 of base 222, however anyother shape is hereby contemplated for use. In the arrangement shown, asone example, lower end 266 is generally square, rectangular,trapezoidal, diamond or another shape and is configured to fit into andsecurely hold onto an opening 42 in the top side 36 of a jig segment 24and/or spacer 48, however any other shape is hereby contemplated foruse. In the arrangement shown, as one example, neck 268 is generallycylindrical in shape and smaller than upper end 264 and lower end 266and is configured to fit within the slot 248 in the keyhole 244 of base222, however any other shape is hereby contemplated for use.

In one arrangement, to secure connection to jig segment 24 and/or spacer48, connector 226 is formed of a compressible material such as a rubber,a synthetic rubber, a rubber composite, a silicone, a plastic, a foam, apolyurethane, or any other compressible and flexible material or anycombination thereof. In one arrangement, to help maintain a connectionbetween connector 226 and jig segment 24 or spacer 48, the material thatforms connector 226 has a high coefficient of friction, which helpsconnector hold onto the surfaces of opening 42.

In the arrangement shown, as one example, to attach clamp pad attachmentmechanism 220 to a jig segment 24 or spacer 48, the lower end 266 ofconnector 226 is aligned with an opening 42 in the top side 36 of a jigsegment 24 or spacer 48. Once aligned, the lower end 266 of connector226 is forced into the opening 42. In doing so, the compressiblematerial of connector 226 deforms, slightly, and engages the surfaces ofopening 42. In this position, the high coefficient of friction of theconnector 226 holds onto the surfaces of the jig segment 24 or spacer 48thereby holding the two components together. To remove the clamp padattachment mechanism 220 from a jig segment 24 or spacer 48, sufficientforce is applied to pull the lower end 266 of connector 226 out ofopening 42. In this way, clamp pad attachment mechanism 220 is quicklyand easily attached to and removed from a jig segment 24 or spacer 48.

Tapering of Components:

In one arrangement, so as to facilitate the removal of components of thesystem 10 from the molds that they are formed in, the components taperslightly as they extend upward. That is, in this arrangement, the partsof the system 10 are slightly wider at their lower side than they aretheir upper side so as to facilitate easy removal from the molds thatthey are formed in. As such, while in some arrangements opposing sidesare identified as being parallel in nature from one another, it is to beunderstood that this parallel alignment may in fact have a slight taperand therefore may not be perfectly parallel, but instead parallel savefor the tapering.

From the above discussion it will be appreciated that the mini pockethole jig system and related method of use, presented herein improvesupon the state of the art.

Specifically, the mini pocket hole jig system presented: providesimproved functionality over prior art systems; provides improvedfeatures over prior art systems; is relatively inexpensive; is easy touse; is intuitive to use; is strong and robust; can be used in manyapplications; is practically impossible to improperly set-up; providesunique functionality; is fast to use and fast to set-up; is safe to use;saves time; has a compact size; is adjustable, in depth as well aswidth; has a long useful life; can be used on outside edges onworkpieces as well as inside corners; is high quality; improvesefficiencies; is fun to use; improves the quality of the products madeusing the device; eliminates the need to review the set-up instructionsto properly set up the system; that provides a visual feedback that thesystem is properly set-up, among countless other advantages andimprovements.

It will be appreciated by those skilled in the art that other variousmodifications could be made to the device without parting from thespirit and scope of this disclosure. All such modifications and changesfall within the scope of the claims and are intended to be coveredthereby.

What is claimed:
 1. (canceled)
 2. A stepped drill bit system for drilling pocket holes, comprising: a stepped drill bit; the stepped drill bit having a shaft; the stepped drill bit extending a length from a connection end to a drilling end; wherein the drilling end is configured to drill into a workpiece; the stepped drill bit having a larger diameter portion; the stepped drill bit having a stepped feature positioned at the drilling end, the stepped feature having a smaller diameter portion; the stepped drill bit having a plurality of indicia that correspond to workpiece thickness; a stop collar; the stop collar having an alignment feature; the stop collar having a securing member; wherein the stop collar is configured to be placed over the shaft of the stepped drill bit; wherein when the stop collar is placed over the shaft of the stepped drill bit, and the alignment feature of the stop collar is aligned with an indicia of the plurality of indicia of the stepped drill bit and secured in place with the securing member, the stepped drill bit is configured to drill pocket holes in a workpiece having a thickness that corresponds to the indicia the alignment feature is aligned with.
 3. The system of claim 2, wherein the connection end is configured to be received in a chuck of a drill.
 4. The system of claim 2, further comprising a workpiece thickness gauge, the workpiece thickness gauge having a plurality of indicia that indicate the thickness of a workpiece.
 5. The system of claim 2, further comprising a workpiece thickness gauge, the workpiece thickness gauge having a plurality of indicia that indicate the thickness of a workpiece; wherein the plurality of indicia on the workpiece thickness gauge correspond to the plurality of indicia on the stepped drill bit.
 6. The system of claim 2, wherein the alignment feature on the stop collar is an opening in the stop collar.
 7. The system of claim 2, wherein the alignment feature on the stop collar is a hole in the stop collar.
 8. The system of claim 2, wherein the alignment feature on the stop collar is a recess in the stop collar.
 9. The system of claim 2, wherein the plurality of indicia of the stepped drill bit are etched into the stepped drill bit.
 10. The system of claim 2, wherein the alignment feature on the stop collar is a circular opening.
 11. The system of claim 2, wherein the plurality of indicia on the stepped drill bit include numerical values that correspond to workpiece thickness.
 12. The system of claim 2, wherein the plurality of indicia on the stepped drill bit include a plurality of rings around the shaft of the stepped drill bit that correspond to workpiece thickness.
 13. The system of claim 2, wherein the securing member is configured to secure the stop collar in position on the stepped drill bit when tightened; and wherein the securing member is configured to permit the stop collar to be moved to a plurality of different positions along the stepped drill bit when loosened.
 14. The system of claim 2, wherein the securing member is a threaded shaft that is configured to extend through the stop collar and engage the stepped drill bit thereby securing the stop collar in place.
 15. A stepped drill bit system for drilling pocket holes, comprising: a stepped drill bit; the stepped drill bit extending a length from a connection end to a drilling end; the stepped drill bit having a shaft having a larger diameter portion and a stepped feature positioned at the drilling end, the stepped feature having a smaller diameter portion; a plurality of indicia positioned on the shaft of the stepped drill bit, wherein the plurality of indicia correspond to workpiece thickness; a stop collar; the stop collar having an alignment feature, wherein the alignment feature is an opening in the stop collar; the stop collar having a securing member; wherein when the stop collar is placed over the shaft of the stepped drill bit, and the alignment feature of the stop collar is aligned with an indicia of the plurality of indicia of the stepped drill bit and secured in place with the securing member, the stepped drill bit is configured to form a pocket hole in a workpiece, having a thickness that corresponds to the indicia of the plurality of indica.
 16. The system of claim 15, further comprising a pocket hole jig having a drill guide; wherein the drill guide is configured to guide the stepped drill bit for drilling the pocket hole in the workpiece at the angle; and wherein when the pocket hole jig is placed on the workpiece the pocket hole is drilled by inserting the stepped drill bit into the drill guide of the pocket hole jig and drilling the pocket hole in the workpiece at the angle until the stop collar engages the pocket hole jig.
 17. The system of claim 15, further comprising a workpiece thickness gauge, the workpiece thickness gauge having a plurality of indicia that indicate the thickness of a measured workpiece.
 18. The system of claim 15, further comprising a workpiece thickness gauge, the workpiece thickness gauge having a plurality of indicia that indicate the thickness of a measured workpiece; wherein the plurality of indicia on the workpiece thickness gauge correspond to the plurality of indicia on the stepped drill bit.
 19. The system of claim 15, wherein the alignment feature on the stop collar is an opening in the stop collar.
 20. The system of claim 15, wherein the alignment feature on the stop collar is a hole in the stop collar.
 21. The system of claim 15, wherein the alignment feature on the stop collar is a recess in the stop collar.
 22. The system of claim 15, wherein the plurality of indicia of the stepped drill bit are etched into the stepped drill bit.
 23. The system of claim 15, wherein the alignment feature on the stop collar is a circular opening.
 24. The system of claim 15, wherein the plurality of indicia on the stepped drill bit include numerical values that correspond to workpiece thickness.
 25. The system of claim 15, wherein the plurality of indicia on the stepped drill bit include a plurality of rings around the shaft of the stepped drill bit that correspond to workpiece thickness.
 26. The system of claim 15, wherein the securing member is configured to secure the stop collar in position on the stepped drill bit when tightened; wherein the securing member is configured to permit the stop collar to be moved to a plurality of different positions along the stepped drill bit when tightened.
 27. The system of claim 15, wherein the securing member is a threaded shaft that is configured to extend through the stop collar and engage the stepped drill bit thereby securing the stop collar in place.
 28. The system of claim 15, wherein the connection end is configured to be received in a chuck of a drill.
 29. A method of setting a stop collar depth for a pocket hole jig system, the steps comprising: providing a stepped drill bit having indicia thereon, wherein the indicia of the stepped drill bit correspond to workpiece thickness; providing a stop collar having an alignment feature; placing the stop collar on the stepped drill bit; aligning the alignment feature of the stop collar with the corresponding indicia on the stepped drill bit corresponding to a thickness of a workpiece and once aligned in the desired position securing the stop collar in place on the stepped drill bit; drilling a pocket hole using the stepped drill bit with the stop collar attached to the stepped drill bit by inserting the stepped drill bit into a drill guide of a pocket hole jig and drilling a hole in the workpiece to a depth at which the stop collar engages the pocket hole jig.
 30. The system of claim 29, wherein the securing the stop collar bit in place includes tightening a fastener of the stop collar.
 31. The system of claim 29, wherein the alignment feature on the stop collar is an opening in the stop collar.
 32. The method of claim 29, wherein the alignment feature on the stop collar is a hole in the stop collar.
 33. The method of claim 29, wherein the alignment feature on the stop collar is a recess in the stop collar.
 34. The method of claim 29, wherein the indicia of the stepped drill bit are etched into the stepped drill bit.
 35. The method of claim 29, wherein the indicia on the workpiece thickness gauge is a plurality of steps, wherein each step corresponds to a particular workpiece thickness.
 36. The method of claim 29, wherein the stop collar is secured in place on the stepped drill bit using a securing member that is a threaded shaft that is configured to extend through the stop collar and engage the stepped drill bit thereby securing the stop collar in place. 